Custom Silicone Table Mat | Russian 2022 Project
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Product |
Food-Grade Square Silicone Table Mat |
|---|---|
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Order Quantity |
Initial Order: 50,000 pcs |
|
Material |
Food-Grade Solid Silicone |
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Key Specs |
Hardness: Shore A50 Temperature Resistance: -40°C to 230°C |
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Certification |
FDA, LFGB, REACH, BPA-Free, PFAS-Free |
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Lead Time |
DFM Evaluation: 24 hrs |
Project details
A Russian kitchen furniture brand wanted to develop a table mat for heat insulation, slip resistance, and protection on kitchen countertops and dining tables. The initial prototypes produced by the client had an attractive appearance, but the edges were uneven in thickness, the corners curled up, and stains were difficult to remove, resulting in a poor user experience.
Z.S.R optimized the sample using DFM (Design for Manufacturing) technology and created the mold, solving the issues of curling edges and oil stain resistance. The finished product meets the requirements for food contact and high-temperature contact.
Based on the DFM results, the project moved into mold making and sample production, followed by quality verification of the first batch before mass production.
Delivery data
Engineering DFM Assessment
Uniform Wall Thickness + Optimized Edge Structure
In the original design, the main body thickness of the mat was 2.0 mm, while the four corners were only 0.8 mm. Inconsistent cooling and shrinkage stress caused the corners to curl upwards. The mat’s wall thickness is now uniformly 2.0 mm, with a 1.2 mm rounded edge thickening, and all corners rounded to R8 mm.
Inconsistent cooling and shrinkage rates at abrupt changes in thickness cause the corners to warp after the release of residual internal stress. Standardizing the wall thickness, combined with rounded edges and large rounded corners, allows shrinkage stress to be released evenly, reducing warping.
Optimized Matte Etching Texture on Mold Surface
The engineering team changed the mold cavity from a mirror surface to a uniform matte etched structure, while also optimizing the silicone material formula to improve stain resistance.
The original glossy mirror finish was glaringly reflective, and its insufficient density made it prone to oil and dirt penetration. The matte etching treatment on the mold surface, combined with stain-resistant modification of the raw material, allows stains on the finished mat to be wiped away with a damp cloth.
Multi-Point Injection + Micro-Venting
Large flat mats are prone to air entrapment during molding, resulting in white spots and bubbles. Z.S.R uses multi-point edge injection, with six evenly distributed 0.02 mm deep venting grooves within the mold cavity. Simultaneously, the upper and lower mold plates are controlled by a constant-temperature oil bath.
Large flat plate molding is prone to air entrapment and insufficient material. Multiple injection points combined with venting channels ensure the melt fills the cavity simultaneously, preventing localized material shortages and white spots. Constant temperature oil bath control of the mold plates ensures uniform plate temperature, reducing warping caused by temperature differences.
Mold Making, Sample Production & Quality Verification
Mold Processing
Z.S.R Group is equipped with 10 advanced CNC machining centers and 4 EDM machines for molding liquid silicone mats. The mold cavity undergoes a uniform matte etching treatment, and the parting surface is high-precision ground to ensure no burrs on the usable front side.
Silicone Molding
Production is supported by 48 solid molding machines, 12 liquid molding machines, and 13 injection molding silicone machines using integrated solid silicone molding, enabling the rapid production of 30,000 silicone table mats within 20 days. Over 10 printing and spraying production lines also allow for printing logos or patterns on the silicone table mats.
Secondary Vulcanization
After molding, the silicone table mats undergo secondary vulcanization at 200°C for 2 hours.
The secondary curing process removes small-molecule volatiles from the silicone, reduces product odor, and ensures the mats meet food contact safety standards.
Quality Inspection
|
Test |
Condition |
Acceptance Criteria |
Result |
|---|---|---|---|
|
Warpage Flatness Test |
Laid flat on a horizontal glass surface, static placement at room temperature for 24 h |
Four-corner warp height ≤ 1.5 mm |
Pass |
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High-Temperature Resistance Test |
Placed in a 180°C oven for 2 h |
No deformation, cracking, or obvious discoloration |
Pass |
|
Stain Resistance & Wipe Test |
Tomato sauce and olive oil left static for 30 min, then wiped with a damp cloth |
No obvious oil residue or obvious discoloration |
Pass |
|
Dimensional Accuracy Inspection |
Caliper measurement of length, width, and thickness |
Tolerance controlled within ±0.15 mm |
Pass |
|
Visual Inspection |
100% inspection of product usage surface and edges |
No bubbles, white spots, flash, or scratches |
Pass |
|
High & Low Temperature Cycling Test |
-40°C and 230°C cycling test |
No cracking, deformation, hardening, or obvious precipitation |
Pass |
|
Food Contact Migration Test |
Laboratory chemical migration testing |
Meets relevant FDA and LFGB requirements |
Pass |
|
Hazardous Substances Test |
REACH, BPA, and PFAS related testing |
Meets project requirements |
Pass |
The production samples passed the specified warpage, high-temperature resistance, stain resistance, dimensional, visual, temperature cycling, food contact, and hazardous substance inspections. In particular, four-corner warp height stayed within 1.5 mm after 24-hour static placement.
Related Silicone Table Mat Product
Customer reviews & feedback
“Hi, yes, I received the table mats. They look great, I love them. Thank you so much for your excellent work. Now I need to find some packing materials to put them away.”
Custom Silicone Table Mat
OEM & ODM solutions for brands, retailers, wholesalers, and Ecommerce sellers. Food-grade silicone table mats with FDA/LFGB/REACH compliance.
Other Project
For industrial-scale production, ZSR Group also operates a dedicated silicone compression molding service for custom silicone parts.
