Zeller International - Dolls Puppets Animation Animatronics Robots Q&A

Specialist in Nontoxic Environmental Chemistry since 1964

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Pioneering Innovative Environmental Products & Technologies For Our Future

Dolls - Toys - Puppets

Animation - Animatronics - Robots

Questions & Answers

Q1. We fill doll bodies with water and would like to replace the water with a water like fluid, is there a substance available?

A1. Yes, several choices are available. These options vary in scope and are for gel filled prosthetic appliances and novelties, squishy-fleshy-fatty human tissue. These are reboundable hydrodynamic shape memory polymer's with elasto-mechancial properties.

These tactile soft fill gels provide pressure equalization and can vary from springy dynamic super soft elastomers with pressure distribution to a slow flow oozy feel.

When squeezed-indented these novel compounds return to their precast original state. Depending upon your design and end result Zeller International produces unique hybrid non-toxic easy to use "sensory polymers" for form/fill in place applications.

Existing pre molded doll parts (i.e. hands, arms, legs, or full body shapes) can be filled with water replacement -colloidal gels, sols, or rubbery polymers.

Each assignment-end result is individualized-"sensory"-thus the reason why we have developed a proprietary range of compounds that meet the needs of any task/project.

Very specialized grades of super stretchy, ooey/gooey exotic formulas have been custom formulated for toy-novelty producers with assignable patents.

Zeller International offers the following formulations:

1. Water replacement fluid-''Aqua Gel II". product code #188a. This is a clear flowable slippery water gel polymer which can be thinned with water or rubbing alcohol Aqua Gel II can be warmed for quick filling- injection loading of preformed doll bodies.

Aqua Gel II™ is a core-backfill water replacement. It feels like water and functions as a water filled doll but remains stable without evaporative shrinking. Aqua Gel lasts for years.

2. Zello ™ product code #317. Zello™ is a clear hot melt soft elastomer which melts on an electric hot plate, gas burner, or in a temperature controlled electric melting pot for continuous daily production melting.

Zello™ gels/cools to a formed dimensional shape and is used to mold parts for complete solid or hollow full size seamless bodies. Zello™ can be slushed or mass cast in rigid plastic molds or flexible RTV silicone rubber molds.

EZ Plastic™, product code #100 is often used for heat resistant accurate molds. Zello™ strips from molds easily without sticking resulting in a dry smooth surface suitable for post finishing with stretchable paints- lacquers.

Zello™ cools/sets to a useable part within 30 minutes or sooner with forced cooling. Zello™ is a "green" recyclable soft stretchy tear resistant elastomer.

Zello™ sets to a shore "A" property of 10 and can be made softer by adding Elastoflex™. product code #217, a liquid softening agent, while Zello™ is hot and flowable. Elastoflex™ is a clear non-plasticizer non- migrating additive for customizing-adjusting the hardness level.

Zello™ as is gels to a springy-bouncy-fatty-fleshy compound and is used as received by most doll makers. Zello™ has been poured against premolded preformed doll parts as a back fill water fill replacement or for a complete doll body. Zello™ accepts pigments for full color flesh
tones.

Zello "HT"™ product code #215

This is similar to regular Zello, product code #317, except Zello "HT"™ gels to a very sticky-tacky-grabby surface. Back filled preformed skins requires assured non-separating bonding.

Zello "HT"™ is a highly tackified adhesive compound which welds-bonds to vinyl's, latex's, and a variety of plastics/rubber surfaces. Zello "HT"™ sticks to Cleartex™, Zeltex™, and many other unknown materials. Zello "HT"™ handles, melts, and looks exactly like regular Zello.

3. Zelly Jelly™, product code #114

A clear super soft hot melt polymer which has similar properties to the Zello™ compounds but very soft and non-adhesive. Zelly Jelly™ is a core/back fill elasto gel formula. Existing skins must be precoated with a banner coating to prevent degradement, rejection, bleeding, or
breakdown of the original host surface.

Zelthane™ product code #129, is a clear, flexible stretchable lacquer. It is used as a prep/prime shield coating to protect vinyl's and preformed thin skins. Zelthane™ is slushed-washed quickly onto the vinyl skin and allowed to dry, then Zelly Jelly™ is poured into the prepared part.

4. Sil Gel™, product code #318

A crystal clear two component fast gelling room temperature curing RTV silicone gel which is mixed 1 to 1 and sets to a Shore "A" of 7. Sil Gel is used for numerous animation/prosthetics and novelty applications.

Q2. I need a skin forming material which can be tinted with flesh colors and then painted or slush cast into existing molds. This can be either a water or solvent based rubber product or maybe something that can be melted and poured to form variable thickness skins.

I have used natural latex rubber and silicone compounds and find these materials shrink and degrade and are also difficult to paint and repair.

Do you have single component materials that last for years and are easy to use?

A2. Yes! There are three choices.

1. Zeltex and Zeltex II

2. The Cleartex System, three formulations = soft, medium, and firm

3. Zello. a melt and pour elastomer

Q3. I model in days using polymer clays such as Sculpty™ and other modeling compounds that are hardened in the oven. I need a post finishing material to glaze-finish my art with a protective polymer which won't rub off or damage the original art.

I would also like to have a protective finish that dries to a non-shiny matte finish. Can I use your Zelthane™ lacquer to coat the clay.

A3. Clay materials can be overcoated with several materials however the possibility exists that process oils in the clay may bleed out leaving the surface of the clay sticky.

This requires pretesting to determine compatibility or rejection of the applied coating. Several choices can be made, first is the protective finish to be microthin and resilient or a rock hard tough cladding? Zelthane™ is often used and it dries to a non-shiny finish. As a lacquer it dries quickly to a resilient flexible permanent coating.

Alternatives include single component and two component finishing materials. Kleer Plaztik™. product code #155. Kleer Plaztik™ is a single component crystal clear fast drying lacquer which dries to a rigid hard mar, scratch, and impact resistant film. Kleer Plaztik™ can be sprayed, dipped, and brushed onto surfaces or into molds for a stiff smooth finish.

Another clear coating is Opti Kleer™. product code #105. Opti Kleer™ is a two component reactive clear epoxy resin which is mixed 1 to 1 by volume resulting in a smooth finish. Opti Kleer™ is UV resistant and can be brushed, sprayed, or dipped.