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Bicast Leather – An Economical Option for Leather Appearance

By: Author Dan Concord

As someone always looking for cost-effective yet appealing alternatives to traditional leather for various projects, I have found that bicast Leather offers an excellent solution. While genuine leather is undeniably impressive, its high price tag and sustainability concerns have driven me to explore other options. However, it is worth noting that natural leathers are generally recommended for their quality and durability.

Bicast leather is a thin layer of split leather fused with a synthetic backing. It is easy to maintain and offers versatility in color and finish. Bicast leather generally costs $1–$5 per square foot, making it an appealing alternative for leather fans on a tight budget.

With so many leather alternatives available in the market, it’s worth taking a closer look at bicast leather to discover its unique features, applications, and benefits. This article will examine its characteristics, history, and production process and offer practical advice on working with this versatile and affordable material.

What Is Bicast Leather?

Bicast leather is made using a thin layer of split leather, covering it with a plastic/synthetic layer of either polyurethane or vinyl. The plastic coating is then embossed (a pattern is pressed onto it) to make it look like top-grain leather.

Bicast Leather is not made entirely of leather and technically not even leather because it is a byproduct of split leather. It is much more affordable than genuine/natural leather and easier to clean because of the synthetic polyurethane or vinyl layer. This layer is resistant to stains and spills and can be easily wiped, unlike genuine leather, which is more porous and can absorb liquids and stains.

What We’ll Explore

  • Clearing up Myths & Misconceptions
  • History of Bicast Leather
  • Bicast Leather Characteristics Quick Reference Table
  • In-depth Characteristics of Bicast Leather
  • Pros of Bicast Leather
  • Cons of Bicast Leather
  • How Bicast Leather is Made
  • Production Stats for Bicast Leather
  • Cost of Bicast Leather
  • When You Might Leathercraft with Bicast Leather
  • Tips for Leathercrafting With Bicast Leather
  • Examples of Goods Made from Bicast Leather
  • My Research on Bicast Leather
  • Bicast Leather Care & Maintenance
  • Helpful Insights on Bicast Leather
  • Key Takeaways
Bicast Leather Samples - Bicast Leather - Liberty Leather Goods
Bicast Leather Samples

Clearing Up Myths & Misconceptions

Myth/Misconception: Bicast leather isn’t “real” leather. This statement is false — bicast leather is made from a split leather backing with a layer of polyurethane or vinyl on top. So it technically could be referred to as a hybrid form of leather.

Some people believe bicast leather is vegan or eco-friendly, but this is a myth. Bicast leather is made from animal hides, and coating it with chemicals like polyurethane or vinyl can be ecologically problematic.

Misconception: Bicast leather is more durable than other types of leather. While it might be more resistant to stains and scratches than some kinds of leather, it is less durable overall and doesn’t last as long as genuine leather.

Bicast leather is cheaper than genuine leather: This is generally true. Bicast leather is less expensive than full-grain or top-grain leather.

Misunderstanding: Bicast leather requires less maintenance than other types of leather. This statement isn’t true. Like all types of leather, bicast leather can still dry out, crack, or lose its sheen without proper care. 

History of Bicast Leather

Bicast Leather’s origins date back to the late 1950s when China began exploring more affordable and artificial leather alternatives. This led to the development of bicast Leather as a promising material in the industry. It gained significant recognition in the 1960s, thanks to companies like DuPont, which introduced a U.S.-designed version of the material in 1964.

Initially finding its place in the garment sector, bicast Leather offered a cost-effective solution for creating shiny shoes, and its versatility and affordability quickly caught the attention of other industries, such as furniture manufacturing. Over time, bicast Leather became popular for various products, including couches, chairs, handbags, and accessories.

However, in recent years, debates around sustainability and quality have prompted consumers and manufacturers to compare their advantages to those of natural leather. While bicast Leather remains an option for budget-conscious projects, the industry continues to innovate and explore eco-friendly alternatives to cater to the diverse needs of today’s consumers.

Bicast Leather Characteristics Quick Reference Table

CharacteristicRating
Natural or SyntheticHybrid (both natural and synthetic)
Surface TextureEmbossed to make it appear more leather-like
Available Thickness (oz/mm)1oz (.4mm) to 2oz (.8mm)
Largest Workable Size25 square feet
Flexibility (1–10)5
Softness (1–10)4
Sewability (1–10)6
Durability (1–10)6
Ease of Maintenance (1–10)9
How Long It Lasts (Daily Use)Varis based on care and maintenance typically from 5 months to 5 years
Available ColorsWide range of virtually any
Waterproofness (1–10)8
Cost per Square Foot ($)$1–$5
Ease of Crafting (1–10)7
Rarity (Common or Exotic)common
Annual Production VolumeN/A
Biggest Exporting CountryChina
Biggest Importing CountryU.S.
Bi cast Leather Characteristics

In-depth Characteristics of Bicast Leather

Natural or Synthetic

Bicast leather is a synthetic material, as it is made by combining a thin layer of split leather with a synthetic backing, typically polyurethane or vinyl. While the leather is natural, the coating gives bicast leather a distinct appearance and characteristics.

Surface Texture

Bicast leather’s surface texture is smooth and uniform, with an embossed grain pattern that mimics the appearance of top-grain leather. The embossing process helps create a consistent, leather-like texture that is visually appealing.

Available Thickness

Bicast leather usually comes in thicknesses of around 1–2 oz (0.4-0.8 mm). This moderate Thickness contributes to its durability and versatility, making it suitable for various applications, such as upholstery, bags, and shoes.

Largest Workable Size 

Bicast leather is typically available in sheets, with sizes ranging from 25–35 square feet. This makes it suitable for larger projects requiring consistent appearance and texture, such as furniture upholstery or larger bags.

Flexibility

Bicast leather has a flexibility rating of six or seven out of 10. While it’s not as flexible as some natural leathers, it’s still reasonably pliable, making it suitable for various applications.

Softness

With a softness rating of about five to six out of 10, bicast leather is relatively soft compared to other synthetic materials but might feel less supple than top-grain or full-grain leather.

Sewability

Bicast leather has a sewability rating of around seven out of 10. Its moderate Thickness makes it relatively easy to sew, but the synthetic coating can sometimes cause issues when sewing by hand or with a machine.

Durability

Bicast leather has a durability rating of six to seven out of 10. While it’s not as durable as top-grain or full-grain leather, it still offers good wear resistance and can last several years with adequate care and maintenance. 

However, a press release published in the Leather Controversy by Richard Stevens suggests that little is known about the durability of bi cast leather. The glues used in bonding the various elements of these sandwich construction leathers require solvents like polyurethane for curing purposes, which can break down into a sticky mess over time and when in frequent contact with body heat and sunlight.

Ease of Maintenance

Bicast leather scores are high in ease of maintenance, with a rating of around eight to nine out of 10. The synthetic coating makes it resistant to stains and spills and can be easily wiped clean with a damp cloth.

Lifespan with Daily Use

The lifespan of bicast leather with daily use is around 5–10 years, depending on the level of care and maintenance provided. While it may not last as long as top-grain or full-grain leather, it is still a relatively durable material that can withstand regular use.

Available Colors

Bicast leather is available in various colors, from classic shades such as black, brown, and tan, to more vibrant red, blue, and green options. The synthetic coating allows for the easy application of various pigments, resulting in a diverse color palette.

Waterproofness

Bicast leather has a waterproofness rating of around seven to eight out of 10. The synthetic coating provides a degree of water resistance, making it suitable for use in environments where it may be exposed to moisture. However, it’s essential to avoid prolonged exposure to water, as this could damage the material over time.

Cost

Bicast leather is more affordable than genuine leather, with costs varying depending on the quality and source. On average, bicast leather costs between $0.75–$5 per square foot. Its lower price makes it an attractive option for those seeking a leather-like material without the higher costs associated with natural leather.

Ease of Crafting

The ease of crafting with bicast leather is rated at around seven to eight out of 10. Its consistent texture and moderate thickness make it relatively easy to work with, whether cutting, sewing, or shaping the material. However, the synthetic coating may pose challenges in specific crafting processes, such as gluing or dyeing.

Rarity (Common or Exotic)

Bicast leather is a common material, as it is widely available and used in various industries, such as furniture, fashion, and automotive. Its affordability and diverse applications contribute to its widespread use and accessibility.

Pros of Bicast Leather

Bicast leather has several benefits when compared to natural leather.

  1. Affordability – Is much less expensive than genuine leather
  2. Easy to Clean – Maintenance and cleaning is relatively quick and easy
  3. Appearance – Furniture makers have noted that one of the main attractions of bicast leather is its appearance, which can be achieved at a lower cost

Cons of Bicast Leather

  1. Less durable than natural leather. Genuine leather furniture lasts for 25–40 years
  2. Prone to splitting and cracking within six to eight months of regular use
  3. Does not age gracefully or develop a patina
  4. Durability varies based on material quality and usage
  5. May initially have a strong chemical odor that fades over time

How Bicast Leather is Made

  1. Bicast leather combines a split leather backing with an embossed polyurethane or vinyl layer. The hide material used in making bicast leather is usually a portion of the fibrous, lower-grade leather that remains when the higher-grade grain layer is split off. 
  2. The production process of bicast leather involves applying a layer of plastic to an embossed release paper, which is called casting paper. Through embossing, a top-grain leather appearance can be achieved or a smooth finish can be created depending on the desired effect. Pigment, foams, and adhesives can be added to the plastic layer as desired. 
  3. Next, split leather is applied, and pressure is exerted on the plastic, which may have been previously dried.
  4. Once the bicast leather cures, the casting paper can be removed to reveal the finished product.

The steps above provide a high-level overview of the process of bicast leather production. The actual manufacturing process may encompass additional steps and technical intricacies.

Production Statistics of Bicast Leather

  1. Volume per year – In 2018, the global market size for bicast leather was valued at USD 24.6 billion, as reported by Grand View Research. This market is projected to grow at a compound annual growth rate (CAGR) of 4.4% from 2019–2025. The demand for bicast leather is driven by its low cost, high durability, and easy maintenance compared to natural leather.
  2. Key country or countries where it is produced – Bicast leather is mainly produced in China, which accounts for more than 70% of global production. Other significant producers include India, Pakistan, Brazil, and Vietnam.
  3. Biggest exporting country – China is also the biggest exporter of bicast leather, followed by India and Brazil.
  4. Biggest importing country – The largest importer of bicast leather is The U.S., followed by Germany and France.

Cost of Bicast Leather

Bicast leather is cheaper than natural leather but more expensive than synthetic leather. The cost of bicast leather depends on various factors such as quality, Thickness, color, finish, and demand.

  1. Square foot: The average cost of bicast leather per square foot ranges from $.75 to $5, depending on the quality and type of bicast leather.
  2. ½ Hide: A half hide of bicast leather measures about 25 square feet and costs about $25–$75.
  1. Full Hide: A full hide of bicast leather measures about 50 square feet and costs about $50–$150.

When You Might Leathercraft With Bicast Leather

  1. You want to make a simple and inexpensive product that does not require much durability or customization.
  2. You want to achieve a uniform and glossy look that matches the style of your product.
  3. You want to experiment with different colors and patterns without spending too much on leather.
  4. You want to practice your leathercraft skills before moving to more advanced materials.

Here is a brief video that clearly shows how bicast leather is layered, and different than natural leather:

Tips for Leathercrafting With Bicast Leather

  1. Use sharp tools when working with bicast leather to reduce strains, tears, and wear
  2. Use a low-temperature iron. Bicast leather is sensitive to heat, so you need to be careful when ironing it. 
  3. Use glue or rivets instead of stitching. Bicast leather is unsuitable for stitching, as the needle holes can weaken the leather and cause it to tear.
  4. Protect the surface. Bicast leather is prone to scratches.

Some Examples of Items Made From Bicast Leather

  1. Shoes
  2. Boots
  3. Sofas
  4. Chairs
  5. Jackets
  6. Coats
  7. Bags
  8. Wallets

My Research on Bicast Leather

Bicast leather is a popular choice in the leather industry for its versatility, durability, and affordable price. During my research, I found that bicast leather is a split leather with a layer of polyurethane or vinyl on top, which gives it a smooth, glossy finish.

Ethics and Environmental Impact

Bicast leather has some ethical and environmental concerns that should be considered when deciding whether or not to use it.

The primary ethical concern with bicast leather is that it is made from animal hides. Animal welfare and rights are essential for many people, and using animal-derived materials in fashion and consumer goods can be controversial. Additionally, the chemicals used to coat bicast leather can harm the environment, including water and air pollution. 

Regarding environmental impact, using polyurethane or vinyl to coat bicast leather can negatively affect the environment. As these chemicals are not capable of biodegrading, they can remain in the ecosystem for extended periods. Additionally, the manufacturing process of polyurethane and vinyl can have a significant carbon footprint.

While bicast leather has some ethical and environmental concerns, it remains a popular choice for its affordability and versatility in the leather industry. It’s up to consumers to weigh the pros and cons and make informed decisions about the products they purchase.

Comparing Bicast Leather to Other Leather Alternatives

One common alternative to bicast leather is bonded leather, made by taking scraps of leather and gluing them together to form a bigger piece. Although bonded leather can be more durable than other alternatives, it is generally considered lower quality than bicast leather due to its higher polyurethane-to-leather ratio, which makes it less breathable and more prone to wear and tear.

In contrast, bicast leather has a layer of polyurethane on top of a layer of split leather, providing better durability and resistance to stains. Faux leather, also known as vegan leather or synthetic leather, is another alternative to bicast leather.

It is typically made from a combination of plastic, fabric, or foam and can be less expensive and faster to produce than bicast leather. However, faux leather is generally less durable and may not have the same look and feel as genuine leather.

Regarding sustainability, bicast leather may have some advantages over genuine leather because it can be produced using a smaller amount of material, and it can help reduce waste by using leather scraps that might otherwise be discarded. However, it is still synthetic and may not be as environmentally friendly as other alternatives, such as mushroom leather or recycled leather.

Ultimately, choosing bicast leather and other alternatives will depend on the desired look, feel, durability, and environmental impact. It is essential to consider these factors carefully when choosing a leather alternative for any given application.

Common Issues and Solutions

Common issues with bicast leather include; 

  1. Peeling
  2. Bubbling
  3. Tears
  4. Cracking
  5. The stickiness of the polyurethane coating

There are some solutions available for these issues. For instance, peel-and-tear damage can be repaired with specialized repair kits containing adhesives and fillers. Bubbling and cracking of the finish can be prevented with proper conditioning and maintenance using specific products recommended for bicast leather.

For the common sticky issue associated with bicast and simulated urethane leathers, refinishing kits specifically tailored to address this problem are available. It’s worth noting that while bicast leather is a durable and cost-effective alternative to genuine leather, it is still a synthetic product, so it’s essential to take care of it properly to ensure its longevity. Check out this video on how to fix bicast leather

Conclusion

Bicast leather is an excellent choice for those looking for a durable and affordable leather alternative. It is easy to clean and maintain and comes in various colors and finishes. However, it is essential to note its environmental impact and consider more sustainable alternatives if possible. With proper care and maintenance, bicast leather can last years and give any project a sleek and modern look.

Bicast Leather Care and Maintenance

How to Clean bicast Leather

Bicast leather can be easily cleaned with a damp cloth and mild soap or detergent. Avoid harsh chemicals, solvents, alcohol, or abrasives that can damage the polyurethane coating. Wipe the surface gently with circular motions and remove any excess moisture with a dry cloth.

Do not rub or scrub too hard, which can cause the coating to peel or crack. You can gently use a soft-bristled brush or a sponge to loosen the dirt for stubborn stains. Following the manufacturer’s instructions, you can also use a leather cleaner designed explicitly for bicast leather.

How to Condition Bicast Leather

Bicast leather does not need to be conditioned as often as genuine leather, but it still benefits from occasional moisturizing to prevent it from drying out and cracking. You can use a leather conditioner suitable for bicast leather, applying it sparingly with a soft cloth and buffing it gently until it is absorbed.

Do not over-apply the conditioner, as this can make the surface sticky or greasy. You can also use a leather protector spray to help repel water and dirt and protect the surface from fading or discoloration.

How to Store Bicast Leather

Bicast leather should be stored in a cool, dry, and well-ventilated place, away from direct sunlight, heat sources, and humidity. Do not fold or crease bicast leather, as this can cause permanent wrinkles or cracks in the coating. Instead, hang it on a padded hanger or lay it flat on a shelf or drawer.

If you need to cover bicast leather, use a breathable fabric such as cotton or linen rather than plastic or vinyl, which can trap moisture and cause mold or mildew. You can also use cedar balls or sachets to prevent odors and insects.

Helpful Insights on Bicast Leather

Is bicast leather durable?

Bicast leather is not as durable as natural leather. It tends to crack and peel over time, especially when exposed to heat, sunlight, or moisture. Unlike genuine leather, it also does not develop a natural patina or richness with age. Bicast leather may last for a few months or years, depending on how it is used and maintained, but it will not last as long as genuine leather.

Is bicast leather the same as faux leather?

Bicast leather is not the same as faux leather, although they are synthetic materials that imitate natural leather. Faux leather is made entirely from synthetic polymers without any natural hide. bicast leather, on the other hand, has a thin layer of split leather underneath the polyurethane coating. However, bicast and faux leather cannot be legally sold or marketed as genuine leather.

Does bicast leather peel?

Yes, bicast leather does peel over time. This is because the polyurethane layer on top of the split leather is prone to cracking and splitting due to wear and tear, temperature changes, humidity, and friction. Once the polyurethane layer peels off, the split leather underneath is exposed and vulnerable to further damage.

What are the advantages of bicast leather?

Bicast leather has some advantages over natural leather, such as:

  1. It is cheaper than genuine leather, making it more affordable for consumers who want a  leather-like look and feel without paying a high price.
  2. It is more consistent in texture and color than natural leather, which may have variations in grain, scars, wrinkles, and marks.
  3.  It is easier to clean and maintain than natural leather, which may require unique products and care to prevent stains, mold, and odors.
  4. It is more versatile in design and appearance than natural leather, which may have color, glossiness, and embossing limitations.

How do you care for bicast leather?

Bicast leather requires some primary care to keep it in good condition and prevent peeling and cracking. Here are some tips on how to care for bicast leather:

  1. Avoid exposing it to direct sunlight, heat sources, or moisture, as these can damage the polyurethane layer and cause fading, cracking, or peeling.
  2. Wipe it regularly with a soft cloth dampened with water or mild soap to remove dust and dirt. Do not use harsh chemicals or solvents that may damage the polyurethane layer.
  3. Apply a protective spray or wax for synthetic leather to create a barrier against stains and scratches. Follow the manufacturer’s instructions on how to apply and reapply the product.
  4. Repair any minor cracks or peels with a repair kit designed for synthetic leather. Follow the manufacturer’s instructions on how to use the equipment and match the color and texture of the bicast leather.

Can bicast leather be repaired?

Bicast leather can be somewhat repaired if it has minor cracks or peels. However, if the damage is extensive or deep, it may not be possible to fix it without replacing the whole covering. Bicast leather cannot be stitched or glued like natural leather, as this may cause further damage to the polyurethane layer. Instead, bicast leather can be repaired with a repair kit that contains a filler compound, a colorant, and a finisher that can seal and blend the repaired area with the rest of the surface.

Can bicast leather be used for upholstery?

Bicast leather can be used for upholstery for furniture such as sofas, chairs, ottomans, and headboards. However, bicast leather upholstery may not be very comfortable or durable compared to natural leather upholstery. Bicast leather upholstery may feel stiff and cold to the touch and may not conform to the body’s shape or cushion. Bicast leather upholstery may also crack and peel faster than natural leather upholstery due to frequent use and pressure.

Key Takeaways

  1. Bicast leather is made with a split leather backing covered with an embossed polyurethane or vinyl layer.
  2. Bicast leather is not the same as faux leather, a purely synthetic material with no natural hide.
  3. Bicast leather may peel over time due to the degradation of the polyurethane layer, especially when exposed to heat, sunlight, or abrasion.
  4. Bicast leather has advantages over natural leather, such as lower cost, higher consistency, and easier maintenance.
  5. Bicast leather requires regular cleaning with a damp cloth, mild soap, and occasional conditioning with a bicast leather conditioner to prevent cracking and peeling.
  6. Bicast leather can be repaired with a bicast leather repair kit, which usually includes a filler, a colorant, and a top coat to seal the surface.
  7. Bicast leather can be used for upholstery but may not last as long as natural leather due to its lower durability and breathability.
  8. Bicast leather is commonly used for shiny shoes, handbags, belts, and jackets.
  9. Bicast leather is also used for automotive applications, such as seat covers, steering wheel covers, and dashboards.
  10. Bicast leather may not perform well regarding breathability and comfort, as it does not allow air circulation and may feel sticky or clammy in hot or humid conditions.

In Closing

While bicast leather does not possess the same durability and aging qualities as genuine leather, it is more resistant to scuffs, stains, and scratches. Moreover, it is significantly more affordable than genuine leather, making it a popular choice for furniture, clothing, and accessory manufacturers. Additionally, bicast leather is easy to maintain and clean, making it an attractive option for households with young children or pets.

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