How Are Clay Mitts and Clay Blocks Made? – Step-by-Step Manufacturing Process

Introduction—What Are Clay Mitt and Clay Block?

Clay mitts and clay blocks are advanced alternatives to traditional clay bars. Designed to make car surface decontamination faster and easier, they are essential tools for car detailing professionals and enthusiasts alike.

Though they differ in shape and thickness, both Clay Mitts and clay blocks are made from the same two core materials using an identical production process.

Raw Material 1: Microfiber Cloth or Foam Base

The foundation of a clay mitt or clay block starts with a high-quality microfiber cloth or EVA foam pad. These materials offer:

• Durability and flexibility
• Gentle contact with the vehicle’s surface
• Ease of handling during the detailing process

Microfiber cloth is commonly used for clay mitts, while EVA foam may be chosen for clay blocks for added firmness.

Raw Material 2: Clay Rubber Polymer Layer

The second key component is the clay-like polymerized rubber layer. This material contains synthetic clay compounds designed to:

• Effectively remove bonded contaminants from car surfaces
• Provide better glide with lubricants
• Resist breakage compared to traditional clay bars

This polymer is non-toxic and designed to be safe on clear coats.

Bonding – Combining Microfiber or Foam with Clay Polymer

The two materials are then combined through a hot lamination or adhesive bonding process:

1. The polymer clay sheet is heated to optimal pliability
2. It is then aligned and pressed onto the microfiber or foam base
3. Special pressure rollers ensure uniform bonding without bubbles or detachment

This integrated layer becomes a single, solid piece that ensures durability during repeated use.

Cutting and Shaping – From Sheet to Mitt or Block

Once the composite material has cooled and set, it is ready for shaping. Using precision die-cutting machines:

• Clay mitts are cut into glove-like shapes or rectangular pads
• Clay blocks are cut into handheld bricks or compact pucks

The only difference between a clay mitt and a clay block lies in their shape and thickness—not the materials or process used.

Quality Control and Packaging

Each item is inspected for lamination quality, edge trimming, and flexibility. Products are then packaged with protective film or resealable bags to maintain cleanliness and extend shelf life. Instructions and usage tips are included for user guidance.

Conclusion – One Process, Two Products

Clay mitts and clay blocks share the same core structure and manufacturing steps. Whether you prefer the ergonomic comfort of a mitt or the simplicity of a block, you can trust that both are made with durable materials, precise bonding, and a focus on safety and performance.

Brilliatech is proud to lead the industry in producing high-quality clay tools that deliver superior results while simplifying the detailing process.