Rubber molding services use a variety of methods and materials to manufacture rubber products

such as seals, grips, and caps. Most production methods pour liquid rubber into a heated, cooled,
expandable, or two-part mold. Temperature, air, or pressure then forms the material into a
finished product. Typically, application requirements such as resistance and temperature
determine which material is used.

Manufacturing Processes
Rubber molding services use a variety of manufacturing processes. Each manufacturing practice
has advantages and disadvantages or may be used for a particular material.

Process

Pros

Blow Molding

Hollow Parts

High Performance Physical

Properties
Economical Mold Design;
Compression Molding
Minimal Material Waste
Low Tooling Cost; Low and
Dip Molding
High Volume Production
High Productivity; Low Unit
Injection Molding
Cost
Liquid Injection
High Volume; Low Unit Cost;
Molding (LIM)
Fast Cure Cycle
Cast Urethane

Transfer Molding

Ideal for Molding w/ Metal

Inserts; Product Consistency

Cons
Limited Uses; Inconsistent
Wall Thickness
Material Specific Molding
Process
Process Time; Low Volume
Production; Excess Flash
Process Time; Precision
Control; Geometry Dependent
Expensive Tooling; Use of Low
Molecular Weight Polymers
Expensive Tooling; Size and
Shape Limitations
Moderate Tooling Cost; Use of
Pre-Measured Molding
Compound

Blow Molding
Blow molding is a process commonly used when parts are hollow in design. Elastomer materials
are injected into a hollow molten tube or "parison." The mold encapsulates the parison while
compressed air blows up the parison like a balloon, forcing it outward to conform to the inside

shape of the mold. After cooling, a hollow part emerges. The injection phase may be used to
form a neck or thread diameter with fine tolerances. The blow molding phase suffers from
tolerance issues resulting in inconsistent wall thickness in larger moldings.

Image Credit: CustomPartNet

Compression Molding
In compression molding, slugs of rubber are pressed between two heated mold halves and the
finished part is then air-cooled. The slugs are sized and weighed for the mold cavity. The solid
material is clamped and cured before a finished piece is ejected.

Image Credit: Flexan Corporation

Cast Urethane
In cast urethane molding, open molds are filled with liquid urethane, an elastomer that provides
excellent wear resistance, high tensile strength and high elasticity.

Image Credit: All-State Industries, Inc.

Dip Molding
Dip molding is used to produce such parts as gloves, grips, and protective caps. The process is
similar to hot dip coating, in which the finished product is the fused elastomer or rubber
material stripped from the dipped mold. Thickness and precision of the finished product is
dependent on temperature of the mold, temperature of the resin, speed of dip (in and out), and
bath time.

Image Credit: Materials & Matter for Curious Designers

Injection Molding
Injection molding, also known as rubber injection molding, forces liquid rubber into a cooled
mold. When the material solidifies, the mold is unclamped and the finished part is ejected.
Multiple plates are used and clamped together in order to segregate the mold cavity from the
runner and injection ports. The liquid rubber flows into a runner in the first plate that feeds the
mold cavity through one or several sprues. The runner and sprues help control an even and
consistent flow of rubber or elastomer material into the mold cavity.

Image Credit: The Rubber Group

Liquid Injection Molding (LIM)

Liquid injection molding (LIM) is a suitable process for high volume production of silicone and
fluorosilicone products and materials. The process is a closed system that involves injection of a
dual component mixture, a catalyst and crosslinker, into a heated and pressurized mold. The two
part mixture has a low viscosity, allowing for smaller runner and sprue volumes. Thermosetting
takes place during a short time span and the end result is a high quality product.

Image Credit: Flexan Corporation

Transfer Molding
In transfer molding, the two mold halves are clamped together and the rubber or silicone is
forced by pressure into a heated mold. A slug is placed in a chamber (called a pot), usually at the
top of the mold. The assembly is placed in a press that applies pressure to the open end of the pot
via a piston-like tool head. The press forces the rubber to flow through one or more spruces into
the heated mold. The mold cavity is then cured for a set time before ejecting the finished part.

Image Credit:Hawthorne Rubber Mfg. Corp.

Material Selection
Elastomers and rubber materials are natural or synthetic polymers with a high degree of
flexibility and viscoelasticity (elasticity). Elastomers are usually thermosets that require
vulcanization, but also include various thermoplastics. Application requirements determine
which natural and synthetic materials rubber molding services use.

Natural rubber materials include:

Polyisoprene, also known as gum rubber, is a common organic compound with the
formula CH2=C(CH3)CH=CH2. It is a mixture of latex and other organic compounds

and is commonly used as the building block for many synthetic rubber and elastomer
materials.

Latex is a colloidal sap produced by the Para rubber tree. Latex is often used in the
medical industry, or for protection against liquids and other chemicals. Garments made of
Latex are often disposable.

Synthetic rubber materials include:

Neoprene is a flexible, twistable compound that provides better burn resistance than
natural materials.

Nitrile and styrene butadiene rubber (SBR) provide good resistance to a variety of
petroleum hydrocarbons.

EPDM is used to withstand damage from sunlight, weathering, and ozone, but does not
possess good resistance to hydrocarbons.

Butyl, an isobutylene isoprene elastomer, is valued for its resistance to water, steam,
alkalis, and oxygenated solvents.

Silicone, a synthetic material available in both solid and liquid forms, is durable and free
of allergens or leachable chemicals.

Fluoroelastomers are similar to silicone in mechanical and physical properties, but offer
improved resistance to fuel and mineral oil. Highly fluorinated, carbon backboned
polymers resist harsh chemicals and provide good thermal stability.

The following table includes typical performance properties of common rubber and elastomer
materials:

Image Credit: Molded Products, Inc.