Expertise in Silicone Compression Molding
Compression molding has been a fundamental process in rubber manufacturing since the industry's inception, remaining one of the oldest and most reliable methods for producing rubber parts. Key process parameters include molding time, temperature, and pressure, with clamp pressures typically ranging from 300 to 400 tons.
Since 1998, Neosilicone has specialized in silicone compression molding, providing customers with an efficient solution for producing liquid silicone rubber prototypes and low-volume production parts. This method enables Neosilicone to scale the production of silicone consumer products effectively, maintaining high-quality standards throughout the manufacturing process.
Preliminary Preparation for Silicone Compression Molding
Product Design for Silicone Molding
To develop a commercially viable silicone product, careful consideration of both design concepts and industrial requirements is essential. Our design team employs advanced CAD software to create detailed models that visualize and refine your product ideas.
We meticulously evaluate various factors such as material selection, color matching, Shore hardness, dimensions, tolerances, molding techniques, and shrinkage rates. Our experienced engineers provide expert guidance on material choices and production specifics, ensuring the design aligns with both functional and aesthetic goals.
Prototyping
The next phase involves adjusting the silicone rubber feedstock mix to align with the final product’s specifications. This step, known as prefab processing, ensures optimal material compatibility with the mold, preventing issues such as excessive thickness or hollow sections in the finished product.
Initially, a prototype mold is crafted, typically an aluminum compression mold, which takes approximately 1-2 weeks to complete. Upon completion, our skilled engineers conduct precision testing and calibration to verify that the mold meets all production criteria.
Compression molds are durable and reusable, designed for extended production runs of silicone products.
Production Process for Silicone Compression Molding
1. Material Preparation
- Kneading and Mixing:
- Manual Mixing: Applied for High Consistency Rubber (HCR) and Liquid Silicone Rubber (LSR) to achieve uniform consistency.
- Metering Mixing Pump: Utilized for precise mixing of LSR components.
- Planetary Gear Mixer (Optional): Employed for thorough blending of HCR or LSR.
2. Material Loading
- Filling Methods:
- Manual Filling: Used to introduce material into the mold cavities.
- Solid Fill: Applied for both HCR and LSR, ensuring accurate material placement.
- Cartridge Fill: Specific to LSR, facilitating efficient loading into the mold.
3. Molding Process
- Vulcanization: The silicone undergoes high-temperature and high-pressure treatment in the mold to achieve the desired properties.
- Automatic Mold Clamping: Ensures consistent mold closure and optimal processing conditions.
- Cooling and Demolding:
- Cooling Template: Utilizes a cooling template and ice-cooled mold to facilitate rapid cooling.
- Demolding: The mold is opened to remove the finished silicone parts.
4. Post-Processing
- Trimming:
- Manual and Frozen Flash Removal: The removal of excess material, with the option of designing the mold for tearable flash if required.
At Neosilicone, we adhere to a meticulously standardized silicone molding process to ensure high-quality outcomes. Our production begins by introducing unvulcanized silicone rubber into a mold cavity. This material is then subjected to controlled pressure, which initiates the curing process. Subsequently, the mold undergoes a high-temperature treatment to achieve the desired cure.
In our workshop, press machines continuously monitor critical parameters such as temperature, pressure, and compression time. These real-time measurements allow us to maintain product tolerances within precise specifications. For non-thermoplastic silicone materials, we incorporate vulcanizing agents to enhance both physical and chemical properties.
The vulcanization process involves forming a stable three-dimensional network structure by cross-linking the carbon-hydrogen bonds in the silicone with sulfur from the vulcanizing agents. This structure provides superior stability compared to unvulcanized silicone rubber. The curing cycles typically range from 30 seconds to 2 minutes, depending on the product's cross-sectional area and size.
Upon completion of the curing process, the LSR (Liquid Silicone Rubber) products are cooled to room temperature. Our quality control team then employs both computer-assisted and manual inspection methods to ensure product quality. This includes post-molding activities such as deburring and additional post-curing processes to finalize the product.
Applications of Silicone Compression Molding
1. Consumer Goods: Silicone compression molding is extensively used in manufacturing everyday items such as kitchen utensils, baby products, and household goods. The process provides durability and flexibility, essential for products requiring frequent handling and high performance.
2. Automotive Components: This technique is ideal for producing silicone seals, gaskets, and other automotive parts. The high-temperature resistance and chemical stability of silicone make it suitable for use in demanding automotive environments.
3. Medical Devices: Silicone compression molding is critical in the medical field for creating components like medical seals, diaphragms, and tubing. The ability to mold silicone into precise, hygienic, and biocompatible parts is essential for medical applications.
4. Industrial Applications: In industrial settings, silicone compression molding is utilized to manufacture various components, including vibration dampers, insulators, and sealing solutions. The robustness and resistance of silicone to extreme conditions make it a preferred choice for industrial applications.
Neosilicone Compression Molding Services
At Neosilicone, we serve as a leading OEM provider for numerous silicone product retailers worldwide. With extensive expertise in silicone rubber product manufacturing, we deliver highly efficient and top-quality compression molding services, ensuring that every silicone component adheres to industry-leading standards.
Our facilities are equipped with a comprehensive array of molding press production lines and an in-house mold workshop. We specialize in offering tailored design and production services for silicone products to meet the unique needs of our clients.
Reach out to us today to receive a competitive quote and discover how we can assist with your silicone product needs.
Plastic Injection Molding Process
We specialize in providing high-precision and complex plastic parts in a shorter time. The plastic injection molding process is straightforward and efficient, capable of producing custom prototypes and end-use production parts within 15 days. The injection machine consists of three main parts: the mold, the injection unit, and the clamping unit. Here are the steps to customize your plastic products through the plastic injection molding process:
Step 1: Injection Molding
Thermoplastic resins are loaded into the injection machine barrel by our operators. They undergo melting, compression, and injection into the mold under predetermined conditions.
Step 2: Demolding
Thermoplastic resins cure in the mold. After the thermoplastic materials are cooled, the parts are demolded. Once demolding is complete, the finished parts fall into a loading bin.
Step 3: Deflashing
Our quality control team meticulously inspects each product, using a testing machine to identify any rough edges. These edges are then trimmed off, ensuring the plastic products are clean and neat.
Step 4: Final Inspection & Packaging
Each part undergoes a final inspection to ensure it meets the required quality standards. Once approved, the products are carefully packaged, ready for shipment to ensure they arrive in perfect condition.
FAQs
Q: How Much Does Plastic Injection Molding Cost?
A: Discover how to reduce the manufacturing costs of your custom parts through our injection molding guide, which explores the key factors influencing expenses such as tooling, materials, and production.
Q: Who Owns the Injection Mold?
A: Customers own all custom tooling they develop, while reusable proprietary components created by the manufacturing partner (MP) become the MP's property. Custom tooling remains at the MP's facility for a minimum of two years, with the option for extension if needed. Transfers to other locations are possible at the requester's expense.
Q; What Is the Process After Ordering?
A: Upon receiving the order, our manufacturing engineers review the statement of work. A case manager is assigned, and a suitable manufacturing supplier is selected. We create a thorough DFM report for approval. After approval, tooling and mold production begin. T1 samples are produced and sent for approval. Upon approval, the rest of the parts are manufactured.
Q: What ISO Certifications Do You Have?
A: Having both ISO 9001 and IATF 16949 certifications showcases our dedication to maintaining rigorous quality management practices and meeting the stringent requirements of our client’s industry.