Silicone Compression Molding
Z.S.R International Group(HONG KONG)CO., LIMITED is a silicone products molding company that has utilized compression molding since the year 2007. Silicone compression molding offers ZSR‘s customers an effective and efficient way to manufacture their liquid silicone rubber prototypes and low-volume silicone production parts. ZSR Group has the ability to produce silicone consumer products to scale by silicone compression molding.
silicone compression molding Services
- compression molding, Insert Molding, silicone compression Over molding
- Single, multi-cavity, and family molds
- Silicone, rubber
- Ideal for serial production of silicone products
- Rapid tool production in up to 2 weeks
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Z.S.R Silicone compression molding Capacities
The compression molding widely used in medical and sanitary products except for Industrial, daily necessities (such as silicone housewares, kitchenware, silicone gifts, etc.), baby products and other fields that require high levels of safety and environmental protection. They are in:
Silicone Housewares Products
We are the silicone houseware products OEM manufacturing brand behind the brands. We are a silicone molding technical support provider.
We offer silicone projects and technical support to the Housewares products industry. We work with the houseware products brand, wholesale, retail chain, gifts store, and product development company offer the silicone housewares products OEM and ODM service to the whole world.
silicone consumer electronic accessories
We are the silicone electronic accessories products OEM manufacturing brand behind the electronic accessories, and phone case brands. We are a silicone molding technical support provider.
We offer the silicone project and technical support to the Electronic accessories products industry. We work with the Electronic accessories products brand, wholesale, retail chains, gifts stores, and product development company offer the accessories products technical solutions to the whole world.
Silicone Pets Product
We offer the silicone project and technical support to the pets products industry, We work with the pets products brand, wholesale, retail chains, gifts store, and product development companies together. We offer the silicone pet feeding/toy/travel/accessories products OEM and ODM service to the whole world.
The silicone pets products that we made include silicone collars, silicone leashes, silicone walk kits, silicone poop bag carriers, silicone dog ID tags, silicone bowls, silicone toys, silicone toys, silicone bolt bites, silicone pets mats, silicone pets feeding plate, silicone pets brush, silicone dog nuzzle.
silicone baby toy products
We offer the silicone project and technical support to the baby products industry, We work with the baby products brand, distributors, wholesale, retail chains, gifts store, product development company offer the silicone baby and kids feeding/toy/travel/accessories products OEM and ODM service to the whole world.
The silicone baby products must be safe. So high-quality baby products must be made of safe and environmentally friendly raw materials, non-toxic, tasteless, and harmless to the human body. We believe that all mothers hope to use high-quality baby products for their babies.
silicone beauty personal care
We offer silicone projects and technical support to the Beauty and Person care industry. We work with the Cosmetic and Beauty brand, wholesale, retail chains, gifts store, product development company offer silicone Beauty tools, Hairdressing tools and Person care accessories, cosmetic accessories, products technical solutions to the whole world.
The silicone beauty products that we made include silicone bath and body brushes, Silicone hairbrushes, Silicone brush cleaning mat pads, Silicone Travel Bottles, Silicone mask brushes, silicone suction holders, Silicone blackhead brushes, Silicone lip brushes. Silicone Collapsible Face Mask Mixing Bowl, Silicone Cosmetic Bag, Silicone bottle holder, Silicone sleeve/holder, Silicone Make-up Bag, Zipper bag, Silicone Cream Jars, Silicone Massage Cup, Silicone Soap mold, Silicone mirror, etc
Outdoor And Sports Products
We offer the silicone molding project and technical support to the Outdoor & Sports Products industry. We work with the Outdoor & Sports Products products brand, wholesale, retail chain, gifts store, and product development company to offer the compression and LSR molded Silicone products technical solutions to the whole world.
The silicone Outdoor products we made include: silicone outdoor container, Silicone collapsible water bottle, Silicone collapsible bowl, Silicone folded cup, Silicone collapsible funnel, Silicone foldable lunch box, silicone holder, Silicone foldable mat, silicone spot shoe cover, collapsible dog bowl, silicone wrist bands, silicone folding travel bowl,. portable silicone folding cup, silicone travel bottle, silicone collapsible coffee cup, etc
After the silicone compression molding, our Post-processing department do the post processing and treatment, such as trimming, grinding, polishing, spraying, inspection,Secondary vulcanization,LOGO or Pattern printing if needed,.Final Quality control and testing,Package and Warehouse.If you would like to know more information:
What is Compression molding
Compression molding has been used to mold rubber parts since the beginning of the rubber manufacturing industry. It is one of the oldest methods still used to mold rubber parts. The process parameters include molding time, temperature, and pressure. Usually, a 300-400 ton clamp pressure is used.
Z.S.R International Group(HONG KONG)CO., LIMITED is a silicone products molding company that has utilized compression molding since the year 2007. Silicone compression molding offers ZSR‘s customers an effective and efficient way to manufacture their liquid silicone rubber prototypes and low-volume silicone production parts. ZSR Group has the ability to produce silicone consumer products to scale by silicone compression molding.
Characteristics Of Solid Silicone
The hardness range of Solid Silicone is 10-80A, with heat resistance, translucent, good processability, easy demolding and good tear strength, etc. Products are generally used to make the protective sleeve as well food contact applications, automotive parts, roller, household appliance parts and other products. There is two kinds of making process for solid silicone rubber.
There are two kinds of making processes for solid silicone rubber.
Precipitated silicone rubber
Fumed silicone rubber
And Precipitated silicone rubber can pass FDA, Fumed Silicone Rubber can pass the LFGB. The FDA (Food and Drug Administration) is standard in America(US FDA is internationally applied)
LFGB is standard mainly for Europe, Silicone products that pass either one of these tests are safe for human use. In terms of pricing, products in LFGB standard will be more expensive than FDA standard, so FDA is more widely used.
The difference between LFGB and FDA lies in the different way of testing methods, and LFGB is more comprehensive and more strict.
Silicone products Design And Materials
Silicone molded products must not only perform as intended but must also be designed from the beginning to be manufacturable. When you design silicone products. You need to consider:
Material Specifications, Grades and Durometer, Part Size, Shot Size, Dimensional Accuracy, Shrinkage, Drafts and Undercuts, Parting Lines, Gates.
By making the right material, color, durometer, dimension, and tolerance choices OEMs can develop molded products that can be reliably manufactured in large volumes — while minimizing scrap rates and their losses. So, there are a few things to consider when deciding on silicone to use for manufacturing. These include the type of silicone (liquid silicone rubber or high consistency rubber), durometer (hardness), and even color. Each of these can have an impact on manufacturability. Z.S.R group we have the experienced Engineer, we will offer our professional selection and suggestion from the material form that fits with the silicone products being made
Silicone Compression Tooling & Silicone Compression Molding
Silicone Compression Tooling:
In Z.S.R Group, we own our in-house silicone tooling workshop allows us to react quickly to customers changing requirements. Customized CNC tooling and EDM machine can fasten the production process.
Silicone compression molding:
Silicone compression molding is the process of placing un-vulcanized silicone material into the cavity of one or both halves of the mold. The mold is then assembled, placed into a heated compression molding press and cycled.It is a manufacturing process used to create a wide range of products made from silicone rubber.The silicone compression molding process is also known as the vulcanization process.Silicone is vulcanized through this process and a part is formed. While this molding process itself is somewhat slower than injection molding, it does yield quick turns on prototype or R&D parts. It also has less costly tooling upfront.
The most cost-effective production method is to create high multiple cavity tooling.
The Process of silicone compression molding
Silicone compression molding includes the following 10 steps:
Most of the silicone mass production compression mold was made by steel. Before you make the silicone compression mold, you should design the molds according to the products requirements. Z.S.R expert engineer can design the mold for you.
Creating a steel mold involves several precise steps.
CNC milling machines carve out the mold’s cavities and cores from steel or aluminum, following the 3D CAD model.
For finer details, Electrical Discharge Machining (EDM) is used. Once the machining is done, the cavities are polished to achieve a smooth finish.
The necessary textures or surface are added through etching, laser engraving or polishing.
In Z.S.R Group, we own our in-house silicone tooling workshop allows us to react quickly to customers changing requirements. Customized CNC tooling and EDM machine can fasten the production process.
The silicone raw materials are in block form, usually milky white. These raw materials cannot be directly hot pressed and need to be added with vulcanizers (ripening agents). During the preparation process, the ingredients must be accurately weighed according to the formula.
Silicone Rubber mixing: Put the raw materials together with the vulcanizer and other required additives according to product requirements. Mix them through a rubber mixer, and the general mixing time is about 30 minutes to ensure that the raw rubber and the compounding agent are evenly mixed.
Cutting: Cut the refined silicone raw materials into the required size. The cut raw materials need to be placed on the wake-up rack for a period of time, usually about 8 hours, to ensure the cleanliness and stability of the raw materials.
Heat the silicone compression mold，Set the silicone production compression mold up the machine and heat it to certain temperature according to this silicone products mass production needed.
After mixing and mold heated, our workers clean the compression mold cavity and cut materials into slices of different lengths and widths according to the weight of the product. Then feeding the material on the compression mold.
After all the material is in the compression mold, The silicone compression mold is closed. This motion is vertically compressing. The pressure is applied to compress the silicone. This pressure causes the silicone to flow and fill the mold cavity completely, taking the shape of the mold. Curing: Heat is applied to the mold, causing the silicone to cure (vulcanize) and solidify into its final shape. Compression molding machines keep the temperature and pressure to cure the material into the shape wanted.
After the silicone product is cured, it is cooled and removed from the mold.
Inspect the formed products to check for stains, missing edges, unripeness, cracks and other defects, and select the defective products.
Remove the burrs of qualified products and remove excess scraps. Ways for deflashing include:
- Manual tearing
- Tumbling
- Precision Grinding
- Cryogenic processing
- Demolding
- Trimming
- Flashing
Depending on product requirements, surface spraying, printing, laser engraving and other processing may be required.
Perform the final inspection of the product to ensure quality, and then package it.
The silicone compression over molding
A: Silicone Over Silicone – First a silicone substrate is molded. Then another silicone is molded onto or around the substrate. The silicone could differ in color and/or hardness.
B: Silicone Over Plastic – First a rigid plastic substrate is molded. Then a soft Silicone is molded onto or around the substrate. This is often used to give a soft grip area to a rigid part.
C: Silicone Over Metal – First a metal substrate is machined, cast or formed. Then, the substrate is inserted into a liquid silicone molding tool and the silicone is molded onto or around the metal. This is often used to capture metal components in a silicone part.
Solid Silicone Rubber Products Production
More than 10 years, Z.S.R Group offer Our Solid Silicone rubber compression molding to the Brands/Wholesalers/Retailers for consumer goods. As we own 20sets of the compression molding machine. we’ve been manufacturing a wide range of silicone products, mainly focused on customized silicone consumer products. Our one-stop silicone products manufacturing factory operates at a high capacity and is focused on producing your personalized silicone products to meet your scalability requirements
Benefits Of Silicone Compression Molding
Good for High Volume Manufacturing: Although this technique has a longer cycle time, it is a low-pressure mold, which means it’s inexpensive to produce a variety of cavities without high tooling costs.
Industries And Applications
It is widely used in medical and sanitary products except for Industrial, daily necessities (such as silicone housewares, kitchenware, silicone gifts, etc.), baby products and other fields that require high levels of safety and environmental protection. They are in :
- Home & housewares & Appliances ( Kitchen & dinning&table & Drink ware &household.etc.)
- Baby & Toys ( Baby care & Baby Feeding & Baby Toy & kids learning toy etc）
- Health & Beauty & Personal Care （Oral care & Beauty tools/Accessories & hair care ,etc.）
- Stationery & Office Products(Arts & Crafts& School products & Office products etc. )
- Sports & Outdoor & Garden ( Sports and fitness & Travelling & Outdoor portable etc. )
- Pets Supplies
- Electronic & Cell Phones Accessories ( Protective cover& Case, holder etc.)
- Automotive & Aerospace & Military
- Smoking products
- Promotional products (Licensed products & Mascot & Gifts & Blind box products)
Solid Silicone products Quality Standards
Material Standard: FDA and LFGB
Size and Tolerances:+/- 0.15 mm Tolerances or according to the 2D drawing request
Surface and Color: Check the surface to see if there is any damage, lack of glue, deformation, different color… and other UN-quality, etc
Custom Silicone Compression Molding Solutions For Your Business
In Z.S.R Group, we work with your timeline and budgets. Our cost-effective prototypes can be populated in small production runs that align with your schedule. We work closely for achieving high-quality custom silicone products for your company. Get in touch to learn more and order your custom silicone rubber products.
