Many fields have benefited from silicone. Products containing silicone are used by millions every day. Products containing silicone are used for a variety of purposes in today’s society. There are thousands of applications for custom silicone across many different industries. The use of silicone products is growing. Silicone is used in many fields due to its non-toxic nature, tastelessness, and thermal properties. This article will help you learn how medical silicone products are manufactured.
Medical silicone products manufacturing methods
Manufacturing silicone rubber products can be done in many different ways. Silicon rubber components are most frequently made by molding, which is a reliable and efficient way to fabricate them. As the material is forced into all corners of the cavity, the pressing pressure keeps the material evenly distributed, while the mold’s heat cures the silicone rubber, resulting in a shape-retaining product. Custom silicone Manufacturers of medical silicone products can use a variety of molding techniques, such as compression molding, injection molding, and extrusion molding. Selection is based on component characteristics, volume requirements, and tooling budget.
1. Compression molding
The most common production method is compression molding. Most of the process is carried out with the help of the mold, which in turn determines what the silicone product will look like.
High-temperature molds are typically used to mold silicone products, which are filled with silicone vulcanizing agents and then vulcanized under pressure, then shaped and vulcanized at high temperatures. Silicone molds have hardnesses between 30°C and 70°C. The process of manufacturing these molds is relatively straightforward and suitable for most medical silicone products. O-rings, cushioning pads, silicone washers, Gaskets, seals, and automotive parts like hoods and fenders are all silicone products.
2. Injection molding
A silicone injection mold is made by injecting silicone material into a heated closed mold after it has been heated. During the injection and curing cycles, a heated mold is closed by an injection press and kept closed while the rubber is injected and cured, the rubber is then injected into the mold using a nozzle. Throughout the mold, the silicone rubber is guided along with runners and a sprue before it is introduced into the mold cavities. This results in the rubber part filling and packing the mold cavity.
As a result, the size, complexity, and applications of the products can vary greatly. Products related to small parts include kitchen tools, automobile parts, and swimming supplies.
3. Extrusion molding
The extrusion molding process is used to create complex cross-sections, profiles, cords, and cording. In addition to their long lifespan and color range, they can withstand a wide range of environments.
Raw materials are extruded using a screw, under the influence of temperature and rotation. The material will pass through the die once it is in the extruder. For curing, it is then passed through a heated chamber. Some chemicals may remain after curing. Custom silicone manufacturers eliminate these chemical contaminants through exposure to cold temperatures for a few hours following the cure period. Post-curing involves washing and cooling the product. After cutting, the product is inspected for quality.
4. Transfer molding
Transfer molding is a specialized process that is used to produce silicone rubber in cavities. A mold cavity is filled with material via this process. A crater is formed when the material cools and assumes the shape of a crater. In a plunger, the material is forced into a cavity using a funnel or sprue. This is done by heating the mold. This material remains inside the mold for the entire curing process. Compression molding is similar to transfer molding. In a transfer molding process, however, the preforms are positioned inside a container called the pot.
5. Calendaring
Calendaring involves creating sheets from products before they are processed into final products. The material is rolled into uniformly thick sheets by means of multiple rollers. Each roller’s speed is determined by the product’s specific requirements.
Conclusion
To summarize, there are a number of variables that determine which method is appropriate for producing medical silicone products. A decision is made in part by considering the quantity, design, cost, and time to deliver the product. All molding processes have pros and cons. producing a finished product requires that you have a thorough understanding of all the subtleties involved with each method.