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Which Moulding Process Should You Use for Your App
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You need to consider a number of factors when trying to figure out which type of rubber moulding process is necessary.

These factors can include the following:

Both the geometry and the size of the part
The overall part weight
What material is required?
What is the required volume of parts?

Rubberised Compression Moulding
Compression moulding was the original way that rubber was moulded. It can be used for producing low or medium volumes and has been used extensively for the moulding of gaskets, O-rings and bulky, large parts. Not only is it efficient in its use, it is economical and can be used for a wide variety of products. That is particularly true of low production volumes of higher cost material or medium to large parts.

Consider the use of cost-effective compression moulding when you see one or more of the following:

Low quantity is required
The bonding application goes from rubber to metal
Extreme hardness of the material is needed
It requires larger parts

Rubber Transfer Moulding
Many people prefer to use transfer moulding because it brings out the best of the injection moulding benefits and the fact that compression moulding is an easier option. Rubber transfer moulding is also preferred in many cases when there are small, delicate parts close to the bonding of metal to rubber or if there are numerous cavities. It may also be preferable if mould cavities would trap air as a result of the part geometry.

The advantages of using transfer moulding in comparison to compression moulding may include the following:

Simpler and fewer preforms because one preform can be used for filling many cavities
Tighter control of dimensional tolerance because of the closed nature of the mould. Since it isn't held open to allow the material to spill out of the cavity it keeps the geometry of the part more precise and allows for smaller parting lines.

Injection Molding
Rubber injection moulding was originally used in the plastic industry in the early part of the 1960s. Some of the initial issues included temperature (rubber is heated, plastics are cooled) and pressure (rubber requires more pressure than plastic).

The 3 types of rubber injection moulding include the following:
When organic rubber injection is used, it is much more efficient in the preparation process. After mixing, the material is stripped and then fed into a screw. That screw continues to charge a barrel when necessary so that a predefined amount of rubber is used. Upon closing the mould, the material is injected from the barrel into the mould cavities, after which curing takes place.

The benefits of using injection moulding include the following:

No need for preforms to be placed by the operator
Preheating of the screw takes place prior to the material being put into the cavities. As a result, the material viscosity is lowered so that the flow is more consistent.
Faster cycle times compared to compression and transfer moulding

LSR injection vs. Liquid Injection Molding (LIM)
A liquid silicone compound of two parts (A & B) is used in this process. They are delivered into a static mixer at a fixed ratio. A platinum cure system is blended with the LSR mixture and it is injected through a runner and gate system after being delivered to the injection unit. This allows for the curing inside of a closed mould. When the cycle is complete, parts are either ejected or removed from the cavities, after which the cycle starts over again.

The benefits of using LIM moulding include the following:

Limited contamination due to an automatic closed-loop system
Parts that are effectively flash-less
Optimization of cycle times
LIM often used for the production of medical products
A cost-effective method of producing complex shapes within high-quality components

Thermoplastic Rubber (TPR) Injection
In this process, thermoplastic elastomers (TPE) are used that offer the benefits of rubber but are processed in a similar way to plastic.

The following are the benefits of using TPE rather than thermoset rubber:

 Easier processing, since vulcanization or mixing are not used
Lower cost of parts because of thinner wall sections and lower density
The TPEs can be coloured
Scraps and parts can be recycled

Latest Activity: Dec 15, 2017 at 6:13 AM

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