Creating Silicone Adult Toys

How We Create Body‑Safe Silicone Toys: The Technical Craft Behind John Thomas Quality

When you’re choosing an intimate product, the material and manufacturing process matter just as much as the design.

At John Thomas Toys, every toy is made from 100% medical‑grade platinum silicone and produced using a highly controlled, technically precise process. This ensures not only safety, but consistency, durability, and exceptional detail.

Below is a deeper look at how professional‑grade silicone toys are made — and why our methods set us apart.

1. Concept & Design: Engineering Fantasy Into Reality

Every product begins with a concept, often inspired by:

• fantasy creatures

• anatomical forms

• natural textures

• customer requests

Design isn’t just about appearance — it’s about ergonomics, surface texture, flexibility, and structural integrity.

We use a combination of:

• CAD modelling for precision

• hand‑sculpting for organic shapes

• prototype testing to refine firmness and feel

This ensures the final design is both visually striking and comfortable for intimate use.

We have used many things as inspiration from every day objects, popular fantasy themes crafted into a John Thomas Toy and even pictures from customers wanting their appendages immortalised.

2. Copper Moulds: The Gold Standard of Detail

Most manufacturers use silicone or resin moulds. At John Thomas Toys, we use solid copper moulds, which offer several technical advantages:

• Superior heat conduction → for better and 'more even' curing

• Exceptional detail capture → crisp textures, smooth surfaces

• Long‑term stability → moulds don’t warp or degrade

• Consistent results → every pour matches the last

Copper moulds are significantly more expensive and difficult to produce, but the quality difference is unmistakable.

3. Preparing the Mould: Cleanliness & Precision

Before each pour, moulds are:

• sterilised

• inspected for micro‑imperfections

• treated to ensure smooth release

• pre‑heated for optimal silicone flow

This level of preparation reduces defects and ensures a flawless finish.

4. Silicone Selection: Medical‑Grade Platinum Cure

Not all silicone is equal. We exclusively use platinum‑cured, medical‑grade silicone, which is:

• non‑porous

• hypoallergenic

• phthalate‑free

• odourless

• long‑lasting

• FDA‑approved

Platinum‑cure silicone undergoes a chemical reaction that produces a stable, inert, body‑safe material with no fillers or by‑products.

We offer three firmness levels:

• Super Soft (available in a limited number of toys)

• Soft

• Medium

Firmness is controlled by precise ratios of additives during mixing. Larger toys naturally feel firmer due to increased mass and density — a normal and expected physical effect.

5. Mixing & Colouring: Controlled Chemistry

Silicone must be mixed with exact timing and ratios to ensure:

• proper curing

• consistent firmness

• bubble‑free texture

Colouring is a technical process too. We use:

• medical‑grade pigments

• metallics

• multi‑pour techniques

• marbling and swirl effects

• edge‑coating for dual‑tone designs

Each colour blend is tested for stability and consistency before production.

6. Pouring: Precision to Prevent Air Bubbles

Air bubbles compromise both safety and durability. To prevent this, we:

• vacuum‑degas the silicone before pouring

• pour slowly and evenly

• use controlled temperature environments

• vacuum‑treat again after pouring

This ensures a dense, smooth, flawless product.

7. Curing: Controlled Heat & Time

Once poured, the mould is:

• placed in a curing oven

• heated to a precise temperature

• left to stabilise for a set period

Curing times vary by size — our largest toys can weigh several kilos and require careful handling - some taking 3 men to remove due to the size of them and having to ensure careful damage-free extraction.

8. Finishing: Quality Control at Microscopic Level

Every toy undergoes a multi‑stage inspection:

• cornflour dusting to reveal surface imperfections

• trimming of excess silicone

• texture and firmness checks

• visual inspection under bright light

• final cleaning and preparation

Only toys that pass every stage are approved.

9. Packaging: Protecting the Final Product

Each toy is:

• shrink‑wrapped

• individually stored

• protected from dust, oils, and environmental exposure

This ensures the product arrives in perfect condition.

Why This Matters

The adult toy industry is full of products made with:

• unknown materials

• cheap silicone blends

• porous fillers

• low‑quality moulds

These can degrade, absorb bacteria, or cause irritation.

Our process eliminates those risks. Every John Thomas toy is:

• 100% medical‑grade platinum silicone

• FDA‑approved

• non‑porous and body‑safe

• hand‑crafted with precision

• made using premium copper moulds

This is why our products last for years and maintain their quality with proper care.