Primary process: Blow Molding. The full route, materials, tolerances and design tips for a hollow toy, with an indicative cost.
Blow MoldingPrimary process
PolymerFamily
7Route steps
+/-0.3mmTypical tol.
A hollow toy is primarily made by Blow Molding. Blow moulding inflates a hot plastic tube (parison) against a mould cavity with air, forming a hollow one-piece part. Below is the full route to make a hollow toy, the materials it suits, the tolerances to expect and the main design points. The route is free, from the finder.
Step by step
How a hollow toy is made
The usual route, raw material to finished part. The amber step is where the hollow toy gets its basic shape.
Material
Select the polymer grade and colourant for the hollow toy and dry the pellets.
Tooling
Cut the steel or aluminium mould that forms the hollow toy.
Blow Molding
Melt the plastic and inflate the parison against the mould to make the hollow toy.
Tooling Medium to high Tolerance ±0.3 to 1mm Lead 6 to 12 weeks
Trim
Trim the edges, flash and any waste material.
Secondary
Where the hollow toy needs them, add inserts, printed graphics or machined details.
Tooling None Tolerance ±0.125mm, to ±0.025mm Lead 1 to 10 days
Assembly
Where the hollow toy joins other parts, snap-fit, weld or bond it into the finished product.
Tooling Low Tolerance good Lead immediate
Inspection
Check fit, finish and any functional dimensions.
Need the real cost for a hollow toy? The free route above is yours. Unlock the full dossier to quote and source it.
Where this process typically lands. Tighter is possible with extra operations like grinding, at higher cost.
Materials
Materials for a hollow toy
Grade
Why it suits this
PET
Clear, strong, recyclable
HDPE
Opaque, chemical
rPET
Recycled
Design
Design tips
General pointers. The full design-for-manufacturing list for a hollow toy is in the dossier.
Over-weight bottle.Light-weight the preform.
Non-standard neck.Use a standard closure finish.
Cost
What a hollow toy should cost
Bottles and hollow parts; pennies at scale, resin weight is the biggest lever. Blow near the filling line.
PER-PART COST vs VOLUME
Per-part cost drops as volume spreads tooling and setup over more parts. The exact figures for a hollow toy at your volume, in your currency, are in the dossier.
MODEL EST.
$0.23 to 0.38per part at 1,000 off
A rough ballpark only. The dossier gives should-cost at your exact volume and currency, with the full breakdown.
GET THE FULL DOSSIER
Everything you need to quote and source it
The free route above is yours. To actually put a number on a hollow toy and buy it well:
Should-cost at your exact volume in 12 currencies, with the material, processing, tooling and overhead breakdown
Who to source from, typical MOQ and lead time, and the exact RFQ checklist to send
A quote checker that tells you if a supplier quote is fair, and the red flags to watch
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A hollow toy is primarily made by blow molding. The route is: Material; Tooling; Blow Molding; Trim; Secondary; Assembly; Inspection.
What does a hollow toy cost?
It depends on size, tolerance and volume. As a rough ballpark it starts around $0.23 to 0.38 per part at 1,000 off and falls with quantity. The dossier gives should-cost at your exact volume and currency. A model estimate, not a quote.
What material is a hollow toy made from?
Common choices are PET; HDPE; rPET.
What is the main process for a hollow toy?
Blow Molding. Bottles, tanks, containers and ducts in high volume.
See the exact route and should-cost for your part
The free finder maps your part to its process and full route. Pro adds should-cost at your volume, sourcing and an RFQ draft.
