Get custom-made molded silicone parts, gaskets, sheets, and rolls from NEWTOP Custom Silicone, using top-performing liquid silicone rubber (LSR) materials and processes. Our experience with liquid injection molding (LIM) means we select only the best LSRs for your components – which benefit from faster cure cycles and outstanding UV and ozone resistance. Plus, liquid silicone can mold intricate parts with ease. Enjoy water-sealing properties that will protect your product like never before. Experience the difference today with NEWTOP Custom Silicone.

What is Liquid Injection Molding?

Silicone injection molding is not only a cost-effective but also a reliable manufacturing process that produces high-quality parts from a variety of silicone materials. It offers several advantages such as faster cycle times, greater design freedom, and improved part quality. Equally important is its role in environmental sustainability since there is little waste generated during its process.

Liquid silicone rubber (LSR) injection molding is a thermosetting process involving two mixed substances. This results in a two-component material, which is heat-treated using a mold conductor and mold to form a finished product. LSR molding components are obtained from Parts A and B, which are typically mixed in equal proportions, and the pigment is added during the blending process before treatment.

silicone rubber manufacturing

The process begins with melting and injecting the silicone material into a pre-formed mold. A mechanical injection unit moves material through a heated barrel into a mold cavity. Elevated temperatures and molding pressures of the liquid silicone shot molding process enhance the cure. As the material cools and hardens, it adopts the shape of the mold, providing accurate reproductions every time. Once the molded object is completed, excess material can be removed. Through additional refinement steps such as machining and polishing, final touches can be added.

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Silicone Injection Molding Tooling Costs

Silicone injection molding is a specialized manufacturing process used to create high-precision parts out of silicone. The tooling required to produce silicone injection molded parts do come at a significant upfront cost. However, this cost is often offset by the high volume and consistent quality of parts that can be produced. Tooling for silicone injection molding is typically made from aluminum or steel and involves creating two halves of a “cavity” that is filled with liquid silicone and cooled. The more complex the part geometry, the more expensive the tooling. However, once the initial tooling cost is incurred, millions of parts can be produced at a very low cost per unit. For companies needing a high volume of silicone parts with tight tolerances, the investment in silicone injection molding tooling is worthwhile.

Injection molding is a fabrication process that produces parts from thermoplastic and thermosetting materials. Feed material is added to a heated barrel, mixed, and forced into the mold cavity using a reciprocating screw or ram injector. Once the injection molded part is finished, it is cured to the configuration of the mold cavity. LSR is an increasingly popular choice for various projects due to its superiority in liquid injection molding (LIM) manufacturing processes. The LIM process begins with a two-part liquid silicon compound (parts A & B – catalyst and base), which is automatically delivered from a container/drums to a static mixer in a 1:1 ratio. The static mixer homogeneously blends the materials, triggering the cure system. Next, the LSR flows into the injection unit, feeding the mold cavity via a runner and gate system. It is then subjected to high temperature and extreme pressure for a predetermined cycle time to ensure optimal vulcanization. Upon completion, the parts are ejected, and the cycle begins again.LIM delivers excellent results and can fabricate precise, near-flashless molded silicone parts and silicone over-molded assemblies at high volumes while maintaining tight tolerances.

Benefits of Liquid Injection Molding (LIM)

Liquid Injection Molding (LIM) is a manufacturing process that involves injecting liquid silicone rubber (LSR) or similar materials into a mold to create various parts and products. This advanced technology offers numerous benefits, from precise accuracy to efficient production.

• High Precision and Accuracy

LIM allows for the production of complex and intricate parts with tight tolerances, ensuring a high level of accuracy and detail in the final product.

• Efficient Production

The LIM process is highly automated, reducing labor costs and increasing production efficiency. This automation also leads to consistent quality across all parts produced.

• Material Versatility

LIM can be used with a variety of materials, including silicone, thermoplastic elastomers, and other synthetic rubbers, allowing for a wide range of applications and end products.

• Durability and Longevity

Parts produced through LIM are known for their durability and resistance to extreme temperatures, UV exposure, and chemical corrosion. This makes them suitable for use in various industries, including automotive, medical, and consumer goods.

• Reduced Waste

LIM produces minimal waste, as the material is injected directly into the mold, and any excess can be easily recycled. This not only reduces material waste but also contributes to a more environmentally friendly manufacturing process.

• Shorter Cycle Times

The LIM process typically has shorter cycle times compared to other molding methods, allowing for faster production rates and reduced lead times.

• Lower Tooling Costs

Since LIM uses relatively low injection pressures, tooling costs are often lower compared to traditional injection molding, making it a more cost-effective option for producing parts.

If you’re looking for high-quality, complex parts and products, Liquid Injection Molding is an attractive manufacturing process that offers several advantages over traditional molding methods.

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