Close this search box.
Vans Inflatable Shoe Product Replica

How are custom Inflatables Made?

Transform your Big ideas into Giant Inflatables in three easy steps!

You have a vision – We convert your idea into a design – Your concept is Brought to life!

Are you looking for a fun, custom inflatable to grab some attention and support your brand? What a great choice! Maybe you are looking for a character or a logo to reflect your brand as an inflatable. Perhaps you would prefer something more functional, such as a bounce house or a jumper. In any case, you might wonder, “How are inflatables made?

Tyre Power 4 x 4 inflatable marquee

How are Inflatable Structures Made?

Custom inflatables, simple or intricate, rely on air alone for support, crafted through intricate production methods. Durability is key, especially for interactive or sports inflatables, often made from PVC-coated vinyl or nylon for strength. PVC-tarpaulin is preferred for outdoor use, while Oxford cloth suits indoor or complex shapes. Let’s explore the inflatable production process.

Inflatable PVC Tarpaulin Material

Step 1: Design

Design is crucial, and modern computer modeling tools are invaluable for bringing ideas to life. Mr Inflatables’ designers translate client concepts into detailed computer illustrations, striving to stay faithful to the original vision while ensuring practical feasibility. The 3D design is then dissected into individual components, which will later assemble to create the custom inflatable. Computer programs aid in calculating the required materials, such as PVC. These digital components are then sent to the printer for production.

Computer Design Inflatable Bird

Step 2: Print

Once the custom inflatable design is finalized, it’s passed on to the print department at Mr Inflatables. Here, each individual piece is meticulously printed. Once printed, the pieces undergo automated cutting using a pattern cutter for precision. Subsequently, the pieces transition to the stitching or welding department, where skilled professionals at Mr Inflatables meticulously assemble them to bring the inflatable to life.

Printing Large Format Inflatable

Step 3: Assembly and Testing

After printing and cutting, the pieces proceed to Mr. Inflatables’ skilled stitching or sealing department. Here, each piece is meticulously stitched or sealed together, adhering closely to the original 3D model design and pattern number. Precision is paramount to ensure that each piece fits exactly as intended, akin to assembling a jigsaw puzzle. Once the inflatable is fully constructed, it undergoes inflation with air at Mr. Inflatables to detect any leaks or faults, ensuring the highest quality and performance.

Inflatable Bird Falcon

Custom Inflatables Manufacturing

What Is the Standard Lead Time?

Our standard amount of time needed to build a custom inflatable is 4 weeks. Firstly we get an idea of your concept by asking a few questions, next we move on to quoting for the custom inflatable. If the quote is accepted we move to the design phase which can take up to one week. When the customer is happy with the design we will move to construction. It usually takes 3 weeks to construct an inflatable.

Priority Service

Some clients are working to tight deadlines and so they require the inflatables to be delivered much faster. If a customer is in a rush, we have a few options available. Firstly they can choose an existing design. Maybe the customer is a beverage company. We have already made many soda can designs in the past so it would be straight forward to apply new graphic to an existing design – This is easy!

If the design is more complex, we can offer an expediated service to ensure the design, production and delivery phases are all prioritised. This Rush Service is at an additional cost and quoted on an induvial basis depending on the complexity of the custom inflatable.

What Materials Are Used to Make Inflatables?

So that you can make the best decision possible for your investment, it is necessary to understand the various aspects of the inflatable manufacturing process. The information below will help you find the answers you need to get the most for your inflatable dollar.

A major factor in choosing a cold-air inflatable is the lifespan. Will the inflatable tear, will it fade in the sun, will it last forever? This all depends on the material chosen for the inflatable.

When thinking about purchasing a custom inflatable, its best to consider the following:

What is the denier of the fabric? Denier relates to the unit of weight, indicating the size of the fibre. The higher the denier, the stronger the fabric.

Is the material strong? Material strength depends on a combination of elements including the denier, the fibres, and the weave. The tighter the weave is, the more durable the fabric will be.

Will my inflatable fade? If the fabric is not treated, it is very likely that your inflatable will suffer fading. The inflatable fabric used by Mr Inflatables contains a UV coating to prevent colour fading under normal conditions. However, no amount of UV Coating can prevent fading completely.

Will my inflatable last forever? With all the advances in inflatables today, we still have not found a way to allow inflatables to last indefinitely. Does the manufacturer offer a warranty. This will give you a good idea of the lifespan of your balloon. Mr Inflatables products are backed with a 24 month warranty, however, many of our customers report using their inflatables successfully five years or more.

Six of the most commonly used inflatable fabrics are:

Rip stop – Rip stop fabric is a 70-denier nylon, usually 1.9 ounce, urethane coated. It is used for very lightweight inflatables and internal construction pieces such as the internal baffles that control and maintain the shape of the inflatable.

Oxford – This inflatable fabric is a 200/210-denier nylon oxford cloth, usually 3.5 ounce, urethane coated. It is used primarily for internal construction pieces such as the baffles mentioned above, but is not well suited for inflatables.

Pack cloth – A 410/420-denier nylon pack cloth that is 7-8 ounce, urethane coated. It is more durable than oxford and is heavier. If you are concerned about weight, oxford is most likely the best choice for you. If you are interested in an inflatable constructed from heavier materials, pack cloth will be the better material to use.

Vinyl-Coated Nylon (7.5 oz) – This PVC coated nylon is normally 7.5 ounce. It is used as the exterior material (what you actually see) for most cold-air, advertising inflatables. It’s lightweight, strong, available in custom colors, and accepts graphics easily. This fabric is well suited for cold air inflatables.

Vinyl-Coated Nylon (9-12 oz) – A PVC coated nylon, usually 10 ounce. This fabric is of medium weight and used on areas requiring additional strength such as the base of a small, indoor inflatable, or the primary fabric of recreational or interactive inflatables such as bouncers and slides.

Polyester Vinyl-Coated  (18-22 oz) – This heavyweight fabric is made from PVC coated polyester, and is usually 18 ounce. Primarily, this fabric is used as a base material, covering areas where inflatables touch the ground. It is also used heavily in interactive inflatables like bouncers and slides.

Ready to elevate your event or promotion