Quick Specs at a Glance
Format
Standard and Custom
Film
BOPET / BOPA / LLDPE
Up to 10 Colors
MOQ
10,000 Units
01. Material Engineering: BOPET and BOPA Barrier Film Substrates
The float window of any foil balloon is determined by the base film, not by the valve alone. Commercial grade foil balloons are built on multilayer composite films that combine biaxially-oriented polyethylene terephthalate (BOPET, often called Mylar) with biaxially-oriented polyamide (BOPA, or nylon). The base film then goes through vacuum metallization, where a micro-thin layer of high-purity aluminum is vapor-deposited onto the surface. The metallic barrier slows helium diffusion through the polymer structure, which is the physical reason a foil balloon holds its shape for weeks while a latex balloon loses buoyancy within hours. The full material comparison is documented in our Mylar versus latex comparison. The format reference across the foil balloon category is on our Mylar balloon line.
BOPET Base Film
High tensile strength, structural rigidity, and heat resistance. The vacuum-metallized surface produces the mirror finish that the category is known for. This is the standard base film for solid metallic retail SKUs.
BOPA Nylon Core
Elastic middle layer that resists pinhole punctures and flex-crack. Nylon-based foil balloons hold up under the mechanical stress of custom shapes and dimensional curves. This is the layer that decides whether a character shape survives the trip.
LLDPE Inner Sealant
The inner layer provides the hermetic weld at the seam and the valve seat. It flows cleanly under thermal welding and forms a continuous seal along the perimeter. The valve formulation is part of the batch record and is documented on request.
02. Standard Commercial Product Categories
We manufacture a fixed catalog of standard commercial shapes and sizes for bulk distribution, retail merchandise programs, and event logistics. The standard shape catalog is documented on our standard shapes foil balloon line.
Standard Shapes
18-inch round, star, and heart geometries. Available in solid metallic colourways, holographic and iridescent finishes, and pastel matte lacquers. High-volume retail programs run on these SKUs.
Letters and Numbers
Giant A-Z alphabet and 0-9 number series across 16-inch, 32-inch, and 40-inch formats. The letter catalog is on the wholesale alphabet foil balloon line, and the SKU-level reference is on the jumbo foil letter balloon line and the jumbo foil number balloon line.
Mini Cup and Stick Balloons
4-inch and 9-inch air-filled mini balloons for florist arrangements, gift hampers, and corporate giveaways. The mini catalog is on the mini foil balloon with stick line, and the accessory reference is on the custom stick balloon line.
03. Custom OEM and ODM Shape Tooling
For brand promotions, licensed IP characters, and corporate mascots, we provide custom molding from a buyer's vector artwork. The custom shape pipeline is documented in full on the custom shaped foil balloon line. Three engineering stages matter for any custom program.
CAD Gas-Volume Modelling
The buyer's 2D concept is translated into a 3D CAD model that simulates the inflation forces on the actual shape. The simulation verifies the displacement volume, which is what determines whether the finished balloon will float with helium or must be air-filled only. The print plate is pre-distorted at this stage so that the graphic aligns correctly once the balloon reaches full volume.
CNC Die Fabrication
The heat-sealing die is milled on high-speed CNC centres to match the simulated stress distribution. Sharp interior corners are replaced with a controlled radius before the die is cut, which distributes tensile stress along the weld instead of concentrating it at a single point. The tooling scope for character and mascot silhouettes is documented on the custom cartoon balloon line.
Sample Review and Mass Production
A physical sample is produced and shipped for buyer review. We support up to two full design adjustments before mass production starts. After the sample is approved, rotogravure presses run the full print volume and the automated weld line runs the mass production batch. Buyers who want a reference case file can review the custom balloon case study page.
04. Rotogravure Print and Surface Finish
Print on metallized film has different constraints than print on paper. Solid colour blocks, fine line detail, and gradient shading each require different cylinder engineering. We run the print on rotogravure presses with electronic web-guide alignment and colour calibration against Pantone reference values per run.
| Printing Factor | Specification | B2B Sourcing Impact |
|---|---|---|
| Colour System | Up to 10 colours, CMYK plus spot | Accurate Pantone matching for corporate logos and licensed IP |
| Ink Durability | Polyurethane-based, flexible surface inks | Resists scratch, ink transfer, and peeling during handling |
| Ink Safety | Water-based, heavy-metal-free formulation | Safe for child-facing retail, tested under SGS RoHS report SHAHG2207652301 |
05. Quality Control and Packaging
Every batch of foil balloons undergoes pressure-hold testing before flat packing. We do not publish a decimal-precise defect figure because that number is batch-specific. A buyer should ask for the actual QA record tied to their production run, not a number pulled from a supplier's landing page. Finished flat balloons are packed in moisture-barrier inner packaging with active desiccant for long ocean transit. The full storage and shipping protocol is documented in our shipping, customs, and warehouse storage FAQ. Toy safety testing scope is on our EN 71 toy safety reference page and chemical safety scope is on our RoHS compliance verification page.
06. Technical Specifications and Procurement Terms
The grid below covers the standard configurations for planning purposes. Gas volumes and lift values are working reference figures. Buyers should confirm the specific tolerance for their production run at quotation stage.
| Nominal Size | Gas Capacity | Float Window |
|---|---|---|
| 18-Inch Round or Shape | Approx. 14 L | Multi-day indoor; per-batch QA record on request |
| 30-Inch Shape or Character | Approx. 34 L | Extended indoor window; per-batch QA record on request |
| 40-Inch Letter or Number | Approx. 42 L | Extended indoor window; per-batch QA record on request |
Float behaviour per size is documented in our float time reference. Air-filled display options are documented in our air versus helium comparison. The handling protocol for retail and event staff is documented in our inflation guide.
Minimum order quantity and contract pricing are determined dynamically based on product dimensions, print colour count, film thickness, packaging format, and total shipment volume. We do not publish a flat price grid. The sourcing economics and duty treatment behind the procurement math is documented in our sourcing economics and taxes reference.
We manufacture at the Jiangsu facility. We ship direct. We do not sell through distributors. If you are sourcing wholesale foil balloons or custom Mylar balloons for retail chain, party brand, event, or e-commerce channels, send the target market, the SKU list, and the order volume you are planning, and we will tell you directly whether the program is viable for your channel. Email xia@foilballoon.cn. Put the market, the SKU list, and the volume in the subject line. An inquiry without a market and a volume is not actionable on our side and will not receive a production-ready answer.
Factory Capacity and Lead Time
Our Jiangsu facility runs approximately 1 million units per month. Standard production lead time for orders in the tens of thousands is around 20 days. Larger volumes require production scheduling review, and lead time is confirmed at order stage. Custom tooling and sample development run approximately 12 days. Minimum order quantity for custom printed production is 10,000 units. Buyers who want to visit the factory are welcome to do so, and we arrange factory visits directly through our sales team.
Direct factory contact for this product line:
Kunshan Fair Craft Products Co., Ltd. | Established 2007 | Jiangsu, China | xia@foilballoon.cn