Silicone Injection Molding Manufacturer
With over two decades of expertise, we specialize in producing custom silicone products through advanced Liquid Silicone Injection Molding.
Our fully automated facility is equipped with state-of-the-art technology, including 85T to 160T vertical liquid silicone injection machines, 250T vacuum molding machines, and a horizontal injection machine. Combined with cutting-edge Liquid Silicone Rubber (LSR) capabilities, we ensure the delivery of high-performance, large-volume silicone products that meet the highest standards of quality and precision.
Why is Liquid Silicone Rubber (LSR) an Excellent Molding Material?
Liquid Silicone Rubber (LSR) is a non-toxic, heat-resistant, and highly resilient thermosetting material known for its exceptional transparency and durability. Its key properties, such as low viscosity, rapid curing, shear thinning, and a high thermal expansion coefficient, make it ideal for Silicone Injection Molding. LSR is also available as a two-component system with high transparency, strength, and tear resistance, further enhancing its suitability for creating high-quality silicone products.
Bio-Compatibility
LSR is ideal for silicone products that come into contact with the human body. It is tasteless, odorless, and meets FDA standards, ensuring safety in medical and consumer applications.
Durability
The robust nature of Liquid Silicone Rubber provides long-term stability and outstanding chemical resistance, making it a reliable choice for silicone products across various industries.
Wide Temperature Range
LSR maintains its properties across a broad temperature spectrum, from -60°C to +250°C, ensuring consistent performance in extreme conditions.
Unique Electrical Properties
Liquid Silicone Rubber excels in applications requiring electrical insulation and protection, making it a superior material for silicone products in the electronics industry.
How Does Liquid Silicone Injection Molding Work?
Liquid Silicone Injection Molding (LSIM) is a precise thermosetting molding process designed to produce high-quality silicone products. This process involves the injection of a two-component liquid silicone rubber mixture into a mold cavity, where it undergoes a rapid crosslinking reaction under high temperature and pressure to form solid silicone components.
1. Component Preparation:
Liquid silicone rubber is stored in two separate containers—Component A, which contains a platinum catalyst, and Component B, which contains methyl hydrogen siloxane. These components are linked to a metering system that automatically dispenses them in a 1:1 ratio. Optional pigments can be added at this stage to achieve the desired color.
2. Machine Customization:
The injection molding machine is tailored to meet the specific requirements of the project, including precise shot sizes. Temperature settings, injection rates, and cycle times are adjusted according to the needs of the silicone product being manufactured.
3. Mold Setup:
The machine heats the mold to the required temperature and adjusts the clamping force as needed. Once the mold is prepared, it is closed, and the liquid silicone rubber is injected into the mold cavity through the pumping system.
4. Curing and Solidification:
During the injection process, the mold maintains a consistent temperature and pressure to ensure that the silicone rubber solidifies properly. This process is repeated as necessary to produce the required volume of silicone products.
5. Post-Molding Operations:
After the silicone products are removed from the mold, they undergo de-flashing, quality control checks, testing, and packaging to ensure they meet all specifications and standards.
Liquid Silicone Injection Molding provides a reliable method for producing high-performance silicone products with exceptional accuracy and consistency.
Cold Runner vs. Hot Runner Injection Molding
In injection molding, the method used to introduce material into the mold significantly impacts the manufacturing process. The two primary systems are cold runner injection molding and hot runner injection molding. Both systems are designed to channel material from the sprue to the mold cavities, but they differ in their approach and application.
Cold Runner Injection Molding
Cold runner systems consist of a mold base with two or three separate panels. In this setup, the thermoplastic or silicone material is injected through a nozzle and sprue, flowing through an unheated runner network to fill the mold cavities.
- Double Plate Cold Runner Mold: This type features a runner and sprue that are connected to the final product. After molding, a pop-up system separates the runner and sprue from the finished silicone product.
- Three-Plate Cold Runner Mold: Here, a stripper plate captures the sprue, ensuring the correct amount of molten silicone is delivered to the cavities. When the mold opens, the flow tract is separated from the silicone products.
Hot Runner Injection Molding
Hot runner systems use heated runners to maintain the material at optimal processing temperatures. This setup includes a manifold system with heating elements to ensure consistent material flow and temperature.
- Two-Plate Hot Runner Mold: This system incorporates a heating tube to keep the silicone at the required temperature throughout the process. The mold opens, and the final product is ejected without additional runner material.
- Internal vs. External Heating: Internal hot runners are ideal for polymers sensitive to temperature fluctuations, while external hot runners offer improved flow control and consistency.
Both cold and hot runner systems offer distinct advantages for producing silicone products, with cold runners being simpler and cost-effective, while hot runners provide enhanced precision and reduced waste.
Advantages of Cold Runner and Hot Runner Injection Molding
Cold Runner Mold:
- Cost Efficiency: Cold runner molds offer high cost-effectiveness, making them a budget-friendly choice for various production needs, including silicone products.
- Low Maintenance: These systems generally have lower maintenance requirements, reducing operational costs.
- Versatility: Cold runners are compatible with a wide range of engineered and thermosetting materials, including silicone.
- Design Flexibility: They provide excellent flexibility for quick design changes and adjustments.
- Rapid Production: Ideal for silicone products, cold runner molds enable efficient mass production with quick turnaround times.
Hot Runner Mold:
- Faster Cycle Times: Hot runner molds significantly reduce cycle times, increasing overall production efficiency for silicone products.
- Reduced Post-Production Costs: These systems lower the need for post-production activities and associated costs.
- Minimized Waste: Hot runners reduce post-production waste, making them more environmentally friendly.
- Enhanced Automation: The automation process is more efficient with hot runner systems, contributing to streamlined production workflows.
Applications of Silicone Injection Molding
1. Medical Devices: Silicone injection molding is extensively used in the medical industry to produce components such as seals, gaskets, and tubing. Silicone’s biocompatibility and durability make it ideal for creating medical devices that require precise, sterile, and reliable performance.
2. Consumer Electronics: In consumer electronics, silicone injection molding is employed to manufacture components like keypads, covers, and seals. Silicone’s flexibility and resilience enhance the durability and tactile feedback of electronic devices, improving user experience.
3. Automotive Parts: Silicone injection molding is utilized in the automotive sector for parts like gaskets, seals, and vibration dampeners. The material’s resistance to extreme temperatures and environmental conditions ensures reliable performance and longevity in automotive applications.
4. Industrial Equipment: Silicone injection molding serves various industrial applications, producing parts such as seals, gaskets, and vibration isolators. Silicone’s ability to withstand harsh conditions and its chemical resistance make it suitable for demanding industrial environments.