In the production of toys and collectible figures, material selection directly affects the final product’s durability, tactile feel, and safety. In particular, a material’s fatigue strength is a critical metric for judging whether a toy can maintain structural integrity and appearance after long-term use, handling, and transport. This guide fully analyzes the fatigue-strength characteristics of commonly used materials and offers application suggestions across different processes and design scenarios to help brand owners, designers, and contract manufacturers make optimal choices.
1.What is material fatigue strength
Material fatigue strength refers to a material’s ability to withstand repeated loading (tension, compression, bending, or torsion) without cracking or failing. For example, if a material with insufficient fatigue resistance is used, the factory production of toys/models made from that material may suffer quality issues caused by the material’s inadequate fatigue properties. Therefore, material fatigue strength is especially important when producing custom toys.
Factors that affect materials: material type, processing/production method, temperature, humidity, load frequency, material formulation, and production time—these critical factors will determine the quality and appearance of your custom toys after factory production.
Importance: This directly determines whether your custom toys are prone to damage when soaked, exposed to high temperatures, subjected to frequent human handling, transported by sea/land/air, or kept in a collection—and whether their fatigue strength remains stable over time after consumers acquire them.
2.Common toy materials and fatigue characteristics
1.PVC (injection-molded plastic):
PVC is one of the most common materials in the toy industry. It has relatively high fatigue strength and good toughness, able to withstand repeated bending and long-term use while maintaining dimensional stability and showing fine surface detail. Because injection molding is a mature process, PVC has clear advantages in mass production: smooth surfaces, high color fidelity, and suitability for a wide range of figures, models, and collectible toys. PVC is also relatively low-cost, enabling budget control while maintaining quality. However, PVC can soften or deform at high temperatures, so temperature control and protective packaging should be considered during design and logistics.
2.Rotocast vinyl / rotational casting (rotationally molded vinyl):
Rotocast vinyl is produced via rotational casting and yields a soft-feeling material with moderate fatigue strength. It is often used for toys of various styles and children’s toys because of its rounded appearance and gentle touch, which convey safety and warmth. Rotocast pieces are typically hollow and lightweight, making them suitable for large-volume or exaggerated-shape toys. However, their wear resistance and structural strength are inferior to ABS or PVC, so they are more prone to scratches or dents and are better suited to display/collectible use rather than high-stress, frequently handled functional toys. In the collectibles market, rotocast vinyl remains a popular material choice.
3.Resin:
Resin can capture extremely high levels of sculptural detail, making it ideal for statues, limited-run collectibles, and premium figures. Its advantage lies in reproducing fine carving textures and complex shapes to meet collectors’ demands for high-end finish. However, resin has relatively low fatigue strength and is brittle; it can crack or break under drops or improper loads. Thus, resin toys are better suited for static display rather than children’s play or frequent handling. Extra protective measures are required during transport and packaging. Despite its fragility, resin continues to be widely purchased by collectors and aficionados because of its premium feel and unique expression.
4.ABS (acrylonitrile butadiene styrene):
ABS is an engineering plastic known for high fatigue strength, impact resistance, and good dimensional stability. It is widely used for building blocks, assembly toys, and functional toys because its robust structure withstands long-term operation and repeated assembly/disassembly. Injection-molded ABS products have high surface hardness and excellent mechanical properties, making them suitable for parts that demand structural strength and precise fits. ABS costs more than common PVC and is slightly heavier, which can increase shipping costs. Overall, ABS balances strength and durability, making it ideal for toys that require high stability and long service life.
5.Silicone / TPR (thermoplastic rubber):
Silicone and TPR are noted for excellent elasticity and fatigue resistance, commonly used for soft components, elastic toys, and products that require a safe, soft touch. They can endure large stretches and repeated deformation without breaking, making them especially appropriate for children’s toys and stress-relief products. Silicone feels soft and skin-friendly and can meet food-grade or infant safety standards; TPR combines rubber-like elasticity with plastic processability, offering advantages in shaping and mass production. However, silicone and TPR processing is relatively complex and more costly than traditional plastics. Nevertheless, thanks to their comfortable feel and high durability, they remain well-suited for high-end custom and safety-focused toys.
3.Effects of different manufacturing processes on material fatigue
Different manufacturing processes not only determine a toy’s appearance and level of detail but also have a significant impact on material fatigue strength. (1) Injection molding is a mature process suitable for PVC and ABS; it ensures structural stability and excellent consistency in large-scale production, making it the typical choice for market products. (2) Rotational casting (rotocast vinyl) imparts a soft feel and lightweight structure, but over long-term cyclic loading the material can deform, so its fatigue life is moderate. (3) Resin casting delivers exceptional sculptural detail, but resin’s inherent brittleness limits its fatigue resistance, so it’s more appropriate for display pieces. (4) 3D printing offers flexibility for rapid prototyping and small-batch customization, but fatigue strength depends heavily on the printing material and layer orientation; process optimization is required to improve part durability.
4.Overall summary of material selection
Overall, different materials have distinct advantages and trade-offs; selecting the right one for custom toys and figures requires a balanced decision based on specific needs. For example, PVC is cost-effective, shows good detail, and has relatively high fatigue strength—making it a first-choice material for mass production. ABS offers impact resistance and high stability for structurally complex or frequently used toys. Resin, though more brittle, provides superior sculptural detail and suits collectible and limited-edition figures. Rotocast vinyl is favored for its soft, safe feel in children’s and retro markets. Silicone and TPR excel in elasticity and safety for soft components and high-safety toys. Companies should consider not only cost and appearance but also target customers, use scenarios, and shipping methods to balance functionality, aesthetics, and durability.
5.Further concerns and contact
If you have additional concerns, please contact our team—we’re happy to answer and fulfill your requirements. You can also consult the table below, which may be helpful. Thank you for reading; we will continue to refine this article based on issues we encounter and hope to meet you again with updated content.
| Material Type | Fatigue Strength Characteristics | Suitable Applications | Advantages |
|---|---|---|---|
| PVC (injection-molded plastic) | High fatigue strength; resists repeated bending; suitable for mass production | Standard figures, models | Advantages: low cost, good detail reproduction |
| Rotocast vinyl | Moderate fatigue strength; soft hand feel | Retro toys, children’s toys | Advantages: gentle touch |
| Resin | Low fatigue strength; brittle and prone to cracking | Collectible statues, small-batch custom pieces | Advantages: extremely fine sculptural detail |
| ABS | High fatigue strength; impact-resistant | Building toys, functional toys | Advantages: high strength, impact resistance |
| Silicone / TPR | Highly elastic; excellent fatigue resistance | Elastic toys, soft components | Advantages: soft feel, durable |
