Custom Reusable Silicone Coloring Mat | French 2020 Project
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Product |
Reusable Silicone Coloring Mat |
|---|---|
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Order Quantity |
Initial Order: 30,000 pcs |
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Material |
Food-Grade Liquid Silicone |
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Key Specs |
Hardness: Shore A45 |
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Certification |
FDA, LFGB, ASTM F963, EN 71-1/2/3, BPA-Free |
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Lead Time |
DFM Evaluation: 24 hrs |
Project details
A well-known French educational supplies brand needed a reusable silicone coloring mat with pre-printed outlines. The mat had to support repeated coloring, washing, drying, and recoloring without deterioration of the printed pattern.
The product supplied by the client’s original manufacturer met the required dimensions and general appearance specifications, but the printing process showed pattern misalignment and print defects.
Based on previous silicone printing projects, Z.S.R Group introduced atmospheric plasma surface activation, selected a two-component screen-printing ink system, and controlled the post-printing curing temperature and time.
The process was developed around two requirements: consistent pattern registration and stable adhesion between the printed ink and silicone substrate.
Delivery data
Engineering DFM Assessment
Silicone Substrate and Printing Surface
Pattern alignment was one of the main issues identified during the initial assessment. The client’s original process involved printing directly onto the silicone surface with conventional screen-printing ink, followed by air drying.
To improve surface consistency and printing stability, Z.S.R Group engineers recommended changing the substrate to liquid silicone. Compared with solid silicone, the selected liquid silicone process provided a more uniform molding surface and more consistent conditions for subsequent printing.
The printing process was then modified to include plasma surface activation, two-component screen-printing ink, and controlled thermal curing after printing.
Plasma Surface Activation
Untreated silicone has low surface energy, which makes reliable ink wetting and adhesion difficult. Atmospheric plasma treatment was applied specifically to the printing area before screen printing.
The treatment modifies the silicone surface and improves its wettability, creating more stable interface conditions for ink application and adhesion. During production, the plasma treatment distance, power, and processing speed were controlled to maintain consistent surface treatment.
Printing was completed within 30 minutes after plasma treatment to limit the effect of surface hydrophobic recovery and maintain the activated surface condition during ink application.
Two-Component Screen-Printing Ink
The conventional ink used in the original process did not provide sufficient adhesion to the silicone substrate. Z.S.R Group replaced it with a two-component screen-printing ink system selected for compatibility with the liquid silicone surface and subsequent thermal curing process.
The ink and curing agent were precisely weighed and mixed thoroughly. The mixture was then allowed to stand to release entrapped air bubbles before printing.
The two-component system provides a more stable cured ink layer on the silicone substrate than the original air-dried conventional ink process. Combined with plasma pretreatment and thermal curing, this reduces the risk of peeling and cracking during repeated washing and handling.
Post-Printing Curing
After screen printing, the mats were allowed to level naturally for 5–10 minutes. They were then cured in an oven at 150°C for 20 minutes.
Controlled thermal curing promotes cross-linking within the two-component ink system and supports the formation of a stable interface between the printed layer and the silicone substrate. Compared with the original air-drying process, this provides more controlled curing conditions for subsequent washing and abrasion exposure.
Mold Making, Sample Production & Process Control
Mold Processing
Z.S.R Group operates 6 advanced CNC machining centers and 4 EDM machining centers for the production of liquid silicone mat molds.
Mold processing was controlled to maintain the required product dimensions and surface consistency, providing a stable substrate for the subsequent pattern-printing process.
Liquid Silicone Molding
Production is supported by 12 liquid silicone molding machines, with capacity to mold 30,000 silicone mats within 20 days.
After molding, the mats proceed to the printing process, where plasma surface treatment is applied before ink deposition. Treatment distance, power, and processing speed are controlled throughout the plasma process, and screen printing is completed within 30 minutes after plasma treatment.
Ink Preparation
The curing agent and two-component screen-printing ink are precisely weighed according to the specified formulation and mixed thoroughly. The prepared ink is then allowed to stand to remove entrapped air bubbles before screen printing.
This preparation step helps reduce print defects associated with incomplete mixing or air trapped in the ink system.
Post-Printing Process
After printing, the ink is allowed to level naturally for 5–10 minutes before the mats enter the curing oven.
Final thermal curing is carried out at 150°C for 20 minutes.
Quality Verification
The finished printed mats were evaluated using an abrasion-resistant water-wash cycle test and a solvent-resistance wipe test.
After testing, no obvious peeling or cracking was observed in the printed pattern
Related Silicone Bag Product
Customer reviews & feedback
The initial trial production order was 3,000 pieces. After receiving the order, the customer commented: “I really like the quality. It’s exactly what I was looking for!” The customer subsequently placed repeat orders.
From 2021 to 2023, we continued to develop different pattern designs, increasing the number of designs from the original 10 to 40, and adding different sizes of mats, from 30*40cm to 20*15cm, 20*30cm, and 40*60cm. In 2025, a repeat order of 10,000 pieces was placed. As of September 20, 2026, we are still working with this French customer.
Custom Silicone Mat
Custom silicone mats for brands, retailers, wholesalers, and Ecommerce sellers. Custom size, shape, texture, logo, packaging and certified silicone materials.
