Our Process
In general, the process of getting a material that meets your specific needs is simple. Once you reach out to our customer service or sales personnel, we will ask you a series of questions to determine the best course of action. We will either be able to offer a material direct from our vast formulation library or design one to meet your needs. Depending on your molding or extrusion process, we will send a sample for your evaluation. These samples can be as small as 100 grams to as large as 100 lbs. Once you have determined the material works as intended, we can begin the order process.
Designing and Sampling
We never charge for material development. We only get paid when you place a production order. In most cases, samples are provided free of charge, although some limitations apply.
HCR and RTV Materials
We offer HCR materials for use in compression, injection, transfer molding, and extrusion. Molding silicone rubber involves several precise steps to create a variety of products. First, the material is placed or injected into a mold cavity, which is typically made of metal. The mold is then subjected to heat and pressure, allowing the silicone to cure and take the shape of the mold. After curing, the silicone part is removed from the mold, trimmed, and inspected for quality. This process can be used for manufacturing a wide range of products, including gaskets, seals, and medical devices.
Extrusion is another common method for processing silicone rubber, particularly for creating continuous lengths of products like tubing, profiles, or gaskets. In extrusion, the HCR (High Consistency Rubber) is fed into a hopper and then forced through a die, which determines the shape and dimensions of the final product. As the silicone passes through the die, it is subjected to heat to facilitate flow and curing. The extruded silicone is then cooled and cut to the desired length. This process allows for high-volume production of consistent, uniform products. Extrusion is often preferred for creating complex shapes or profiles that would be difficult or costly to produce using other methods. Overall, both molding and extrusion are vital processes in silicone manufacturing, offering versatility and precision to meet the diverse needs of various industries.
We also offer one- and two-part RTV materials. Two-part silicone RTV (Room Temperature Vulcanization) materials offer versatile options for various applications due to their ease of use and ability to cure at room temperature. Here are some common methods for utilizing these materials:
Molding and Casting
One of the primary uses of two-part silicone RTV materials is for mold-making and casting. The material is mixed according to the manufacturer’s instructions, poured over the original model or prototype, and allowed to cure. Once cured, the silicone mold can be used to cast replicas in various materials such as resin, plaster, or even low-temperature metals like pewter.
Potting and Encapsulation
Two-part silicone RTV materials are also employed for potting and encapsulating electronic components or delicate assemblies. The material is mixed and poured around the component to protect it from environmental factors such as moisture, dust, and vibration. This method provides excellent protection while maintaining flexibility to accommodate any thermal expansion or contraction.
Sealing and Gasket Making
Due to their excellent flexibility and chemical resistance, two-part silicone RTV materials are used for creating seals and gaskets in various industries. The material is dispensed directly onto the surface or between mating parts, where it forms a durable, flexible seal upon curing. This method is particularly useful in applications requiring resistance to extreme temperatures, oils, and solvents.
Adhesive Bonding
Some two-part silicone RTV formulations are designed for adhesive bonding applications. These materials are mixed and applied to bonding surfaces, where they cure to form strong, flexible bonds. Silicone adhesives are commonly used in automotive, aerospace, and electronics industries for bonding substrates with different coefficients of thermal expansion or where vibration damping is required.
Coating and Surface Protection
Two-part silicone RTV materials can also be used as protective coatings for various substrates. The material is applied to the surface using methods such as spraying, brushing, or dipping, forming a durable barrier against moisture, corrosion, and abrasion. This method is often used in marine, industrial, and aerospace applications for protecting critical components and structures.
Strand Sealant and Water Blocking
One and Two-Part RTV materials are often used in wire and cable construction to prevent fluid migration within the construction. These materials are used in automotive and marine applications as well as many others.
Overall, the versatility, durability, and ease of use of two-part silicone RTV materials make them indispensable in a wide range of manufacturing, repair, and maintenance applications.
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Let us build a custom silicone solution for you.
We specialize in creating tailored solutions in silicone manufacturing for our customers, with projects ranging in size from large scale industrial to small-business needs. Our decades of experience make us a proven partner and a trusted industry leader in silicone manufacturing. Let us put together a customized solution that meets the specifications of your project today.