Battery Bank Caps
Soft PVC dip moulded Battery Bank Caps manufactured by Vijaya Sai DIP…
View Products
Since 2008
Dip Moulding Solutions
Innovative, reliable, and customized components For Every Industry
Your Ultimate Source for all types of soft PVC DIP Moulded components
Services:
Standard Components
Custom Components
Dip Coating
Our Products
Soft PVC Dip Moulded Components
With a modernized workshop and upgraded technology, we manufacture a wide range of soft PVC dip moulded components with desired thickness, texture, colour, and hardness.
View all products
Battery Terminal Covers
Soft PVC dip moulded Battery Terminal Covers manufactured by Vijaya Sai DIP…
View Products
Bellows
Soft PVC dip moulded Bellows manufactured by Vijaya Sai DIP Moulding, Hyderabad.…
View Products
Bird Protection Caps
Soft PVC dip moulded Bird Protection Caps manufactured by Vijaya Sai DIP…
View Products
Busbar Shrouds
Soft PVC dip moulded Busbar Shrouds manufactured by Vijaya Sai DIP Moulding,…
View Products
Connector Covers
Soft PVC dip moulded Connector Covers manufactured by Vijaya Sai DIP Moulding,…
View Products
Coupler Covers
Soft PVC dip moulded Coupler Covers manufactured by Vijaya Sai DIP Moulding,…
View Products
Crocodile Caps
Soft PVC dip moulded Crocodile Caps manufactured by Vijaya Sai DIP Moulding,…
View Products
Gland Covers
Vijaya Sai Dip Moulding is a leading manufacturer of Gland Covers.
View Products
Handle Grips
Soft PVC dip moulded Handle Grips manufactured by Vijaya Sai DIP Moulding,…
View Products
Lug Covers
Soft PVC dip moulded Lug Covers manufactured by Vijaya Sai DIP Moulding,…
View Products
Plastic End Caps
Soft PVC dip moulded Plastic End Caps manufactured by Vijaya Sai DIP…
View Products
Protection Caps
Soft PVC dip moulded Protection Caps manufactured by Vijaya Sai DIP Moulding,…
View Products
Railway Fuse Covers
Soft PVC dip moulded Railway Fuse Covers manufactured by Vijaya Sai DIP…
View Products
Ring Terminal Covers
Soft PVC dip moulded Ring Terminal Covers manufactured by Vijaya Sai DIP…
View Products
Terminal Sleeves
Soft PVC dip moulded Terminal Sleeves manufactured by Vijaya Sai DIP Moulding,…
View ProductsNeed a custom PVC component?
We manufacture to any specification — thickness, texture, colour, and hardness. Free samples available for qualifying orders.
About Us
Specialists in Dip Moulding Since 2008
We are a professionally managed company, run by young technocrats. Vijaya Sai DIP Moulding has all the infrastructures to develop and manufacture all types of soft PVC DIP Moulded components like Terminal Sleeves, Connector Covers, Battery Terminal Caps, Coupler Covers, Protection Caps, Ring Terminal Caps, etc, for sectors like Automobiles, Battery, Electrical, Electronics, Cutting Tools, Gift articles, and Custom made components etc.
Quality Assured
High-grade quality products with strict quality checks at every stage of manufacturing
350+ Product Types
Wide range of soft PVC components with custom sizes, colours, and hardness on request
Soft PVC Expertise
Specialist in flexible soft PVC dip moulding with desired thickness, texture, colour and hardness
Custom Solutions
Custom-made components as per customer requirements meeting all industry norms
17+
Years of
Experience
Experience
350+
Product
Variants
Variants
450+
Connector
Cover Models
Cover Models
10+
Industry
Sectors
Sectors
Industries We Serve
Dip Moulding Solutions Across Every Sector
Vijaya Sai DIP Moulding supplies soft PVC components to Automobile, Battery, Electrical, Electronics, and Construction sectors — with custom solutions available for any industry requirement.
View all industriesAutomobile
Vijaya Sai DIP Moulding supplies precision soft PVC components — including Battery Terminal Covers, Connector Covers, Ring Terminal Covers —…
Aerospace
Lorem ipsum dolor sit amet, consectetur adipiscing elit. Sed do eiusmod tempor incididunt ut labore et dolore magna aliqua. The…
Battery / UPS
Vijaya Sai DIP Moulding supplies precision soft PVC components — including Battery Terminal Covers, Battery Bank Caps, Vinyl Dip Coating…
Electrical
Vijaya Sai DIP Moulding supplies precision soft PVC components — including Bird Protection Caps, Lug Covers, Crocodile Caps — tailored…
Electronics
Vijaya Sai DIP Moulding supplies precision soft PVC components — including Connector Covers, Terminal Sleeves, Vinyl Dip Coating — tailored…
Construction
Vijaya Sai DIP Moulding supplies precision soft PVC components — including Protection Caps, Thread Protection Caps, Plastic End Caps —…
Material
Soft PVC Dip Moulding
All our products are manufactured from high-grade soft PVC flexible material using the dip moulding process. We offer custom thickness, texture, colour, and hardness to meet your exact requirements.
Soft PVC
The foundation of every Vijaya Sai product. Standard soft PVC delivers excellent flexibility, reliable electrical insulation, and a 5-year shelf life. Shore hardness, wall thickness, colour, and texture are all fully customisable — making it the go-to grade for battery caps, connector covers, terminal sleeves, and general-purpose dip-moulded components.
Standard Grade
RoHS
REACH
Govt. Norms
Key Properties
77 ± 3
Shore A
Shore Hardness
300 – 520
%
Elongation
14 – 19.5
MPa
Tensile Str.
−20 / +90
°C
Temp. Range
Characteristics
| Specific Gravity | 1.25 |
| Tear Strength | 35 Kg/cm² (ASTM D624) |
| Flexibility | No cracks after aging |
| Colour Options | Any custom colour |
| Custom Hardness | Adjustable to spec |
| Shelf Life | 5 Years |
| RoHS Compliant | Yes |
| REACH Compliant | Yes (10 Elements) |
Typical Applications
- Battery terminal caps & covers
- Connector covers & boots
- Ring terminal caps
- Terminal sleeves (Flag, Round, L-Type)
- Handle grips & tool sleeves
- End caps for tubes and pipes
- Protection caps (bolt, rebar)
- General dip coating on metal parts
FR Grade
Flame-retardant soft PVC achieving UL 94 V-0 — self-extinguished within 12 seconds in standardised burn tests. Tested per ASTM D149 / IEC 60243, this grade combines fire safety with the proven flexibility of dip-moulded PVC. Temperature service range −10 °C to +150 °C as certified on our VSDM test report.
Flame Retardant
UL 94 V-0
IEC 60243
RoHS
REACH
Key Properties
V-0
12 Sec
UL 94 Rating
30.5
kV/mm
Dielectric Str.
76
Shore A
Shore Hardness
−10 / +150
°C
Temp. Range
Characteristics
| Flammability | UL 94 V-0 (12 sec) |
| Dielectric Str. | 30.5 kV/mm |
| Insulation | 9 kV (IEC 60085) |
| Volume Resistivity | 1×10¹⁰ Ohm/M |
| Tensile Strength | 18 MPa |
| Elongation | 380% |
| Tear Strength | 35 Kg/cm² |
| RoHS / REACH | Compliant |
Typical Applications
- Busbar insulation shrouds
- Electrical terminal covers
- High-voltage connector boots
- Panel wiring & switchgear covers
- Railway fuse covers
- Industrial cable end caps
UV Grade
Stabilised against ultraviolet degradation, this grade shows no fading or surface breakdown up to 1,000 hours of accelerated UV exposure per ISO 4892-3. UV intensity tested at 0.67 W/m²/nm (UVB 313). Rated "Outstanding" for weatherproofing per ASTM D3045 — the choice for outdoor or sunlight-exposed installations.
Weather Resistant
ISO 4892-3
ASTM D3045
RoHS
REACH
Key Properties
1,000
Hrs (ISO 4892-3)
UV Stability
0.67
W/m²/nm
UV Intensity
77 ± 3
Shore A
Shore Hardness
O/S
ASTM D3045
Weather Proof
Characteristics
| UV Stability | No fading – 1,000 hrs |
| UV Intensity | 0.67 W/m²/nm |
| Weather Proof | Outstanding (ASTM D3045) |
| Colour Retention | Excellent |
| Tensile Strength | 14 – 19.5 MPa |
| Elongation | 300 – 520% |
| Shelf Life | 5 Years |
| RoHS / REACH | Compliant |
Typical Applications
- Outdoor electrical terminal covers
- Bird protection caps (11 kV / 33 kV)
- Overhead line insulation covers
- Exterior cable end caps
- Agricultural & open-air fittings
- Solar panel wiring protectors
Thermal Grade
Formulated for extended service at elevated temperatures, this grade withstands 90 °C continuous use without surface cracking, blistering, or bubbling, and passes heat deformation testing at 130 °C for 4 hours (ASTM D648). Cold resistance is verified to −25 °C — suitable for applications spanning from sub-zero storage to hot industrial environments.
High Temperature
ASTM D648
RoHS
REACH
Key Properties
130
°C / 4 hrs (ASTM D648)
Heat Deform.
90
°C (No surface defects)
Continuous Use
−25
°C
Cold Resist.
77 ± 3
Shore A
Shore Hardness
Characteristics
| Continuous Temp. | 90 °C (no defects) |
| Heat Deform. Temp | 130 °C / 4 hrs |
| Cold Resistance | −25 °C |
| Flexibility | No cracks after aging |
| Weather Proof | Outstanding |
| Tensile Strength | 14 – 19.5 MPa |
| Shelf Life | 5 Years |
| RoHS / REACH | Compliant |
Typical Applications
- Automotive under-hood terminal covers
- Engine bay connector boots
- Industrial oven wiring insulation
- Heat-exposed busbar shrouds
- Boiler & furnace cable end caps
- High-ambient protection caps
Dielectric Grade
Optimised for maximum electrical insulation performance. Tested to 30.5 kV/mm dielectric strength (ASTM D149 / IEC 60243), 9 kV insulation level (IEC 60085), and a volume resistivity of 1×10¹⁰ Ohm/M (ASTM D257). The preferred grade wherever high-voltage safety, arc resistance, or tracking prevention is a design requirement.
High Insulation
ASTM D149
IEC 60243
IEC 60085
RoHS
REACH
Key Properties
30.5
kV/mm (ASTM D149)
Dielectric Str.
9
kV (IEC 60085)
Insulation
1×10¹⁰
Ohm/M (ASTM D257)
Vol. Resistivity
77 ± 3
Shore A
Shore Hardness
Characteristics
| Dielectric Str. | 30.5 kV/mm |
| Insulation Level | 9 kV (IEC 60085) |
| Volume Resistivity | 1×10¹⁰ Ohm/M |
| Flammability | UL 94 V-0 |
| Tear Strength | 35 Kg/cm² |
| Elongation | 300 – 520% |
| Specific Gravity | 1.25 |
| RoHS / REACH | Compliant |
Typical Applications
- HV busbar insulation shrouds
- Lug covers & crocodile caps
- Bird protection caps (11 kV / 33 kV)
- High-voltage terminal covers
- Switchgear insulation boots
- Power distribution cable caps
Matte Grade
A surface-engineered soft PVC grade that produces a uniform, non-reflective matte finish. Retains all core mechanical and insulation properties of standard soft PVC while eliminating glare — preferred where aesthetics, anti-slip grip, or reduced light reflection are requirements alongside electrical protection.
Non-Reflective
RoHS
REACH
Key Properties
Matte
Non-reflective
Surface Finish
77 ± 3
Shore A
Shore Hardness
300 – 520
%
Elongation
−20 / +90
°C
Temp. Range
Characteristics
| Surface Finish | Uniform matte |
| Anti-Glare | Yes |
| Colour Options | Any custom colour |
| Tear Strength | >35 Kg/cm² |
| Tensile Strength | 14 – 19.5 MPa |
| Electrical Insul. | Good |
| Shelf Life | 5 Years |
| RoHS / REACH | Compliant |
Typical Applications
- Handle grips & ergonomic sleeves
- Tool coating & anti-slip covers
- Consumer-visible terminal caps
- Panel-mounted component covers
- Medical device grip components
- Aesthetic dip-coated assemblies
Hard Grade
Higher plasticiser concentration is reduced to raise the Shore A hardness above standard grades, producing a stiffer wall with improved dimensional stability under compression. Tear strength remains above 35 Kg/cm² (ASTM D624). Suited to protective caps and covers that must resist deformation under load or repeated insertion cycles.
Rigid PVC
ASTM D2240
RoHS
REACH
Key Properties
85 – 95
Shore A
Shore Hardness
>20
MPa
Tensile Str.
>35
Kg/cm²
Tear Strength
−15 / +90
°C
Temp. Range
Characteristics
| Shore Hardness | 85 – 95 Shore A |
| Dimensional Stab. | High |
| Tear Strength | >35 Kg/cm² |
| Tensile Strength | >20 MPa |
| Specific Gravity | 1.25 – 1.30 |
| Colour Options | Any custom colour |
| Shelf Life | 5 Years |
| RoHS / REACH | Compliant |
Typical Applications
- Thread & bolt protection caps
- Plastic end caps (tubes, pipes)
- Heavy-duty connector covers
- Coupler covers under compression
- Rebar & stud protection caps
- Tight-tolerance insulation boots
Glossy Grade
A surface-engineered soft PVC grade that cures to a high-gloss sheen, giving components a premium appearance without compromising core mechanical properties. Tear strength and tensile performance match the standard grade. Ideal for visible consumer-facing components or branded assemblies where finish quality matters.
High Gloss
RoHS
REACH
Key Properties
Gloss
High-sheen
Surface Finish
77 ± 3
Shore A
Shore Hardness
300 – 520
%
Elongation
−20 / +90
°C
Temp. Range
Characteristics
| Surface Finish | High-gloss sheen |
| Colour Options | Any custom colour |
| Tear Strength | >35 Kg/cm² |
| Tensile Strength | 14 – 19.5 MPa |
| Electrical Insul. | Good |
| Specific Gravity | 1.25 |
| Shelf Life | 5 Years |
| RoHS / REACH | Compliant |
Typical Applications
- Consumer-visible battery terminal caps
- Branded handle grips & sleeves
- Premium connector cover assemblies
- Retail-packaged protective caps
- Decorative dip-coated components
- Automotive interior trim covers
Chemical Grade
Compounded to resist attack from concentrated acids and alkalis without visible reaction, as verified on the VSDM material test report. Combined with a 5-year shelf life and full RoHS / REACH compliance, this grade is suited to battery, electroplating, and chemical-processing environments where component surfaces are regularly exposed to aggressive media.
Chemical Resistant
RoHS
REACH
Key Properties
None
No Reaction (Conc.)
Acid Resistance
None
No Reaction
Alkali Resist.
5
Years (No changes)
Shelf Life
77 ± 3
Shore A
Shore Hardness
Characteristics
| Acid Resistance | No reaction (Conc.) |
| Alkali Resistance | No reaction |
| Volume Resistivity | 1×10¹⁰ Ohm/M |
| Tear Strength | 35 Kg/cm² |
| Tensile Strength | 14 – 19.5 MPa |
| Shelf Life | 5 Years (No changes) |
| RoHS Compliant | Yes |
| REACH Compliant | Yes (10 Elements) |
Typical Applications
- Battery bank caps & terminal covers
- Electroplating rack covers
- Chemical plant cable protectors
- Lug covers in corrosive environments
- Acid-bath insulation boots
- Industrial vinyl dip coating
Case Studies
Success Stories
Real projects. Measurable results. Every component we produce carries a commitment to quality that our clients can quantify.
500
+
Projects Completed
0
Industries Served
0
+
Years Manufacturing
FAQ
Frequently Asked Questions
Everything you need to know about our dip moulding process, materials, and ordering. Can't find your answer? Our technical team will respond within one business day.
Still have questions?
Our engineering team is ready to help with technical specifications, sample requests, and custom requirements.
Ask a QuestionDip moulding is a manufacturing process in which a heated metal former (mandrel) is dipped into a tank of liquid compound — typically PVC plastisol, latex, or nylon — then withdrawn, cured in an oven, and stripped from the tool. The coating thickness is controlled by the former temperature, compound viscosity, dwell time, and the number of dip cycles. The result is a seamless, flexible or rigid polymer component that precisely mirrors the geometry of the former.
Dip moulding is especially well-suited to elongated tubes, caps, end protectors, grips, boots, and sleeves — anything with a tapered or parallel cross-section that can be stripped from a rigid former. Complex undercuts and internal threads are achievable with segmented or soluble tooling. We routinely produce parts ranging from 8 mm diameter finger-cots to 1.2 m cable-management boots for industrial infrastructure.
A single dip typically deposits 0.5 – 2.0 mm of material depending on compound viscosity and former temperature. Multiple dip cycles build wall thickness progressively; we routinely achieve 0.3 mm minimum (medical thin-walled parts) up to 6 mm for heavy-duty industrial coatings. Uniformity across the part length is ±10 – 15 % of nominal thickness on standard grades, tighter on controlled-process medical work.
Yes. We regularly reverse-engineer existing components — whether from a worn sample, a drawing, or a 3D scan file. Our toolmakers can produce matched tooling and we carry out first-article inspection against the original to confirm dimensional and functional equivalence before volume production begins.
Our standard compound portfolio covers: Standard PVC Plastisol (Shore 40–95 A), Medical-Grade Plastisol (phthalate-free, FDA 21 CFR), Flame-Retardant Plastisol (UL 94 V-0), Natural Latex, Nylon 11 (PA 11, bio-sourced), and Nitrile (NBR). We also work with specialist compounds — including low-odour, food-contact, and high-temperature formulations — where project requirements exceed our standard range. Contact us to discuss non-standard material needs.
Plastisol and latex compounds are fully pigmentable. We can colour-match to any RAL, Pantone, or British Standard reference, or match a physical colour swatch using spectrophotometric measurement. A colour-match charge applies for initial development; approved colours are held on record for repeat orders. Nylon 11 is available in black, natural ivory, and a limited range of standard colours; full custom colour requires a minimum batch commitment.
Temperature range varies by compound: Standard Plastisol operates from −20 °C to +80 °C; FR Plastisol to +100 °C continuous; Natural Latex from −50 °C to +70 °C; Nylon 11 and Nitrile (NBR) both cover −40 °C to +120 °C, making them suitable for automotive underbonnet and offshore applications. If your operating environment falls outside these ranges, contact our technical team to discuss alternative formulations.
We are certified to ISO 9001:2015 across all manufacturing processes. Medical-grade compound work is produced under additional traceability controls aligned with ISO 13485 and EU MDR documentation requirements. Our FR grades carry UL 94 V-0 classification and IEC 60332 compliance. We are also RoHS and REACH compliant across our standard compound portfolio. Full certification documentation is available on request with any quotation.
Every production batch undergoes visual inspection and dimensional checking against the approved first-article report. Depending on specification, additional tests may include: Shore hardness (ASTM D2240), tensile strength and elongation (ASTM D412), wall thickness by cross-section or ultrasonic gauge, dielectric strength for electrical grades, and colour-match verification by spectrophotometer. We provide a certificate of conformance with each shipment and full test records on request.
Yes. All incoming compounds are lot-coded on receipt; lot numbers are carried through job cards, inspection records, and despatch documentation. For medical and aerospace customers we provide complete material traceability from raw compound certificate through to finished-goods batch number. Our quality management system retains records for a minimum of 10 years (25 years for medical device components).
MOQs depend on part complexity and compound type. For standard plastisol parts on existing tooling, we can accommodate runs from as few as 100 – 500 pieces. Specialist compounds (medical-grade, FR, Nylon 11) typically require 500 – 2,000 pieces minimum to justify compound preparation overhead. There is no volume ceiling — we supply everything from small clinical batches to multi-million-part automotive programmes. Contact us for a no-obligation quote on your specific requirement.
Standard aluminium tooling is typically completed in 3 – 5 weeks from approved drawing. Steel tooling for high-volume or abrasive compounds takes 5 – 8 weeks. Tooling is charged at cost as a one-off fee; ownership passes to the customer on full payment, and tools are held in our facility at no charge for the duration of an active supply relationship. We retain 3D CAD of all tooling for rapid replacement if a tool is damaged.
Once tooling is qualified and a first article approved, repeat production orders on our standard compounds run in 2 – 4 weeks. Medical and FR grades requiring specialist compound preparation may require 4 – 6 weeks. We operate a scheduled-release programme for regular customers, which can reduce effective lead time to under 1 week for forecasted volumes. Expedited production is available on request, subject to capacity.
No questions match the selected category.
Start Your Project Today
Need Soft PVC
Dip Moulded Components?
Contact Vijaya Sai DIP Moulding for competitive pricing on all types of soft PVC dip moulded components. Our team in Hyderabad is ready to deliver custom components as per your requirements.
24h
Quote Turnaround
100%
Satisfaction Rate
NDA
Available
Net30
Payment Terms