Quick Specs at a Glance
Format
Round / Star / Heart
Film
BOPET / BOPA / LLDPE
Up to 10 Colors
MOQ
10,000 Units
01. The Three Foundation Geometries: Round, Star, Heart
Round, star, and heart configurations are the highest-volume core inventory in the global foil balloon category. They carry the widest range of retail applications: supermarket seasonal endcaps, party store walls, event arch backdrops, and retail checkout impulse purchase. For importers and retail buyers, a reliable supply of the three base shapes is the foundation of the category. The geometry of each shape carries different mechanical loads during inflation, and the tooling has to account for that. Buyers building the full catalog can review the Mylar balloon line for a general format reference.
Round Geometry
Circular seams distribute gas tension evenly around the full perimeter. This is the most stable of the three shapes under temperature cycling, and it is the format most often used for high-volume retail programs.
Star Geometry
Each point is a stress concentration zone. The corner radius at every tip is machined to a controlled curve during tooling, and the seam is reinforced at the point where the tip meets the body. This is what keeps the tip from tearing during a temperature drop.
Heart Geometry
The inward dip at the top of the heart concentrates tensile stress. The interior radius is engineered with an optimized curve so that the balloon reaches full inflation without puckering at the valley. The result is a smooth mirror-like contour that photographs cleanly.
Custom silhouettes outside the three base shapes use the same tooling workflow documented in our custom shaped foil balloon line.
02. Multi-Layer Film Engineering for Helium Retention
The float window of any foil balloon is determined by the film stack, not by the valve alone. Single-layer films allow helium to diffuse through the polymer structure over time. The envelope in this product family runs a multi-layer co-extruded film with three functional layers tuned to gas retention and mechanical durability. The material comparison between foil and latex is documented in our Mylar versus latex comparison.
Metallized Aluminum Layer
Vacuum-deposited aluminum on the outer surface produces the mirror finish and reduces gas diffusion through the film. Thickness is controlled per run and documented in the batch record.
BOPET Outer and BOPA Middle
The BOPET outer layer provides structural rigidity and holds the shape under sustained internal pressure. The BOPA nylon middle layer absorbs impact and distributes stress along the welded seam. The two layers together are what determine whether the balloon survives ocean transit and retail handling.
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 full perimeter. The valve formulation is part of the batch record and is documented on request.
03. Compostable Option for Regulated Markets
Several EU and North American markets apply single-use plastic levies or Extended Producer Responsibility schemes to festive decor. For buyers sourcing into those markets, this product family is available in a PLA/PBAT substrate instead of the standard BOPET laminate. The compostable line uses the same valve architecture and inflation workflow, so it drops into existing assembly operations without retooling at the buyer's end. The material comparison between PLA/PBAT and conventional film is documented in our compostable foil versus latex sourcing guide.
The material is tested under SGS ISO 14855-1 biodegradation test report SHMR220700361301, issued on 08 October 2022. The PLA-based film reached an average biodegradation of 77.8 percent over a 45-day test cycle at 58 degrees Celsius, with a biodegradation rate relative to the cellulose reference material of 101.4 percent, judged Pass against the ISO 14855-1 validity criteria. Buyers who require the complete EN 13432 industrial compostability package, including disintegration and ecotoxicity testing, should state that requirement at the quotation stage so that the correct submission scope is scheduled.
The report scope is explained on our SGS test report reference page, the film chemistry is documented in our PLA/PBAT material whitepaper, and the chemical safety scope is on our RoHS compliance verification page.
04. Sizing Grid and Lift Performance Reference
The sizing grid below covers the standard configurations. Gas volumes and lift values are working reference figures for planning; buyers should confirm the specific tolerance for their production run at quotation stage.
| Shape and Size | Film Structure | Gas Capacity | Float Window |
|---|---|---|---|
| 18-Inch Round | BOPET / BOPA / LLDPE | Approx. 12.7 L | Multi-week indoor; per-batch QA record on request |
| 18-Inch Star | BOPET / BOPA / LLDPE | Approx. 11.3 L | Multi-week indoor; per-batch QA record on request |
| 18-Inch Heart | BOPET / BOPA / LLDPE | Approx. 11.9 L | Multi-week indoor; per-batch QA record on request |
| 32-Inch Jumbo Round | BOPET / BOPA / LLDPE | Approx. 65.1 L | Extended indoor window; per-batch QA record on request |
| 30-Inch Jumbo Star | BOPET / BOPA / LLDPE | Approx. 52.4 L | Extended indoor window; per-batch QA record on request |
05. Quality Control and Packaging
Every batch of standard shapes 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.
06. PMS Print and Surface Finishes
Solid metallic colours run as standard stock. Custom brand artwork, corporate mascot logos, and seasonal graphics are processed on rotogravure presses with electronic web-guide alignment and colour calibration against Pantone reference values per run. The presses support dual-sided print, which matters for retail display where the balloon rotates on the shelf, and metallic lacquers including gold, silver, rose gold, and pastel matte finishes.
Registration Control
Electronic web-guide alignment holds per-run registration. Fine brand detail and multi-colour logos stay crisp at retail viewing distance. Per-batch registration documentation is available on request.
Colour Calibration
Ink viscosity and colour are calibrated against Pantone reference values per production run. Colour variance documentation is available on request per batch.
Ink Compliance
Water-based, heavy-metal-free inks. Printed film and valve components are tested under SGS RoHS report SHAHG2207652301. Toy safety scope is documented under SGS EN 71 report SHTY130500007975-01. Buyers sourcing into North America should request the ASTM F963 and CPSIA test package as a separate submission, which we commission per order.
Adjacent seasonal SKUs are commonly bundled with standard shape programs in the same production run, which reduces tooling cost per design when the calendar is planned. The adjacent lines for reference are documented under the seasonal families: custom Halloween foil balloons, custom Christmas foil balloons, Valentine's Day foil balloons, custom birthday foil balloons, custom graduation foil balloons, and custom starburst foil balloons. Custom brand shape scope is documented in the custom balloon case study page.
07. Pricing Model and What to Send When You Inquire
Stock metallic colours run without extra plate fees. Custom Pantone matching, glitter patterns, and holiday or brand graphics are processed on rotogravure presses, with plate costs amortized across the order volume. Large importers often consolidate standard shapes with seasonal SKUs and accessories in flat-packed FCL shipments, which lowers the freight cost per unit. The cost structure and duty treatment behind the sourcing 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 standard shapes foil 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