Plastic Dip Coating: The Hidden Hero Behind Safer, Stronger, and Smarter Tools

Created at : Aug 25, 2025

Plastic dip coating has become a widely adopted solution across industries that demand reliable protection, comfort, and performance from their tools and equipment. From enhancing grip on hand tools to providing temporary corrosion resistance during shipping, this process has proven its versatility over decades of use. Understanding its origin, purpose, and the different types available helps highlight why dip coating remains an essential finishing method in manufacturing and beyond.

The Origin of Plastic Dip Coating

The development of plastic dip coating can be traced back to the mid-20th century, when industries began seeking cost-effective alternatives to painting, plating, and rubber molding. The rise of plastics such as PVC and vinyl made it possible to apply protective, flexible layers to metal surfaces by dipping them into a liquid or powdered plastic material.

Initially, the process was valued for its ability to add corrosion protection and insulation at a fraction of the cost of more permanent finishing methods. Manufacturers soon discovered that dip coatings not only extended the service life of tools but also improved their usability. Over time, the practice expanded into both permanent coatings, which remain on tools throughout their lifespan, and strippable coatings, designed to be peeled away once the protection is no longer needed.

The Purpose of Plastic Dip Coating

The enduring popularity of dip coating comes from its ability to serve multiple important functions simultaneously:

1. Improved Grip and Comfort
   One of the most common applications of dip coating is on hand tools such as pliers, screwdrivers, and wrenches. The plastic provides a soft, cushioned surface that enhances comfort during prolonged use. The textured, non-slip finish also reduces the risk of tools slipping from the user’s hands, especially in oily or wet conditions.
2. Electrical Insulation
   Certain types of dip coatings, particularly PVC-based ones, create an insulating barrier that helps protect users working near electrical currents. Insulated handles on pliers, cutters, and screwdrivers are a direct result of this application.
3. Corrosion and Wear Protection
   Bare metal tools are vulnerable to rust, chemical attack, and general wear. Dip coatings form a protective shield that extends the life of the tool, especially in harsh environments such as workshops, marine settings, and construction sites.
4. Customization and Identification
   Dip coatings are available in a wide range of colors, enabling manufacturers and users to color-code their tools. This is useful for quick identification, branding, or even safety coding in workplace environments.
5. Temporary Protection During Storage or Shipping
   Strippable dip coatings serve a unique role in protecting cutting edges, precision-machined parts, and delicate surfaces during transportation and storage. Once the part is ready for use, the coating can be peeled away easily without leaving residue.

Permanent vs. Strippable Dip Coatings

At the core of plastic dip coating technology are two broad categories: permanent coatings and strippable coatings. Each serves a distinct purpose, and understanding the differences is essential when selecting the right option.

Permanent Dip Coatings

Permanent coatings are designed to remain on the tool for the duration of its service life.

• Materials Used: Polyvinyl chloride (PVC), vinyl plastisol, and rubberized plastics.
• Process: Tools are pre-heated, dipped into liquid plastisol or powder, and allowed to cool or cure. The heating level and dipping time control the thickness of the coating.
• Applications: Tool handles, grips for sports equipment, electrical insulation, and corrosion protection.
• Benefits: Long-lasting comfort, durability, and safety.

Strippable Dip Coatings

Strippable coatings are intended to provide temporary protection and can be removed before use.

• Materials Used: Special PVC or latex-based formulations that peel away cleanly.
• Process: Tools or parts are dipped at room temperature, and the coating dries into a peelable layer. No heating is required.
• Applications: Protective edge covers for blades, drill bits, saw teeth, and precision-machined parts.
• Benefits: Prevents rust, scratches, and contamination during shipping or storage without altering the tool permanently.

Types of Plastic Dip Coating Processes

Dip coating can be applied in several different ways, depending on the desired outcome and the type of plastic used.

1. Liquid Plastisol Dip Coating

• Involves immersing a heated tool into liquid plastisol, which fuses and bonds to the surface.
• Creates a flexible, durable, and colorful coating.
• Commonly used for tool handles and grips.

2. Powder Dip Coating (Fluidized Bed)

• A pre-heated tool is dipped into a bed of fluidized plastic powder.
• The powder melts and bonds to the surface, forming a thick, protective coating.
• Ideal for thicker, more durable finishes on tools and industrial equipment.

3. Room-Temperature Strippable Dips

• Parts are dipped into a room-temperature liquid coating that air-dries.
• Forms a soft, peelable protective layer.
• Used for temporary storage and transport protection.

Specialty Dip Coating Options

As industries evolved, so did the demand for specialized dip coating solutions. Some advanced formulations include:

• UV-resistant coatings for outdoor tools and equipment that are constantly exposed to sunlight.
• Chemical-resistant coatings for environments such as laboratories, chemical plants, or food processing facilities.
• Color-coded dips that allow fast identification of tool types, sizes, or ownership.

These options provide even greater customization, ensuring that the coating not only protects the tool but also enhances its usability in specific working conditions.

Permanent vs. Strippable Dip Coatings

Durability:

Permanent Dip Coating: Long-lasting, bonded permanently to the tool

Strippable Dip Coating: Temporary, designed to peel off

Materials

Permanent Dip Coating: PVC, vinyl plastisol, rubberized plastics

Strippable Dip Coating: Specialized PVC or latex formulations

Application:

Permanent Dip Coating: Heated tool dipped into plastisol or powder

Strippable Dip Coating: Room-temperature dip, air-dried

Common Uses:

Permanent Dip Coating: Tool handles, electrical insulation, corrosion resistance

Strippable Dip Coating: Protection of blades, drill bits, and machined parts during storage/shipping

Benefits:

Permanent Dip Coating: Comfort, safety, corrosion protection, grip

Strippable Dip Coating: Prevents damage, easy removal, no permanent alteration

The Lasting Value of Plastic Dip Coating

Plastic dip coating remains an invaluable finishing process because it addresses multiple challenges with one simple solution. Whether used to provide a durable, cushioned grip on pliers or to temporarily protect a precision-machined surface during shipping, dip coatings are both practical and cost-effective.

The ability to customize coatings for comfort, durability, insulation, or temporary protection ensures that this process continues to evolve with the needs of modern industries. Its versatility has made it a mainstay in manufacturing, construction, transportation, and countless other sectors.

Conclusion

From its origins as a mid-century industrial finishing method to its present-day role across a wide range of applications, plastic dip coating has proven to be more than just a protective measure. It is a multifunctional solution that enhances safety, improves usability, extends the life of tools, and ensures parts arrive in perfect condition.

By choosing the right type of dip coating—permanent or strippable—manufacturers and end-users alike can maximize the value of their tools and equipment. With ongoing advancements in materials and application methods, plastic dip coating continues to provide a blend of protection, performance, and practicality that few other processes can match.