Injection Rubber Moulding
Injection moulding machines are either vertically or horizontally run.
Injection moulding is a process where heated elastomer is injected into a closed cavity via a runner system.
Uncured elastomer is fed into the injection cylinder where it is preheated and accurately metered into the mould.
This is done by controlling the pressure, injection time and temperature.
The material is then held under high pressure and at a raised temperature to achieve curing.
When this is complete, the formed parts are ejected from the cavities.
- Suitability for moulding delicate parts
- Shorter cycle times compared with compression moulding
- High levels of automation that can be introduced in the process – reduces labour content
- Lower levels of flash since the mould is shut when the material is injected
- Lower unit costs
- Higher tool and set up costs
- Longer changeover times tooling is more complex with more associated ancilliary equipment
- More waste sprues and runners take the material to the mould and extensive material purging is required when changing colours. However, with the use of a cold runner block material wastage can be greatly reduced
Frequently Asked Questions
What material do you recommend for injection rubber moulding?
For injection rubber moulding, we recommend using high-quality silicone or natural rubber, depending on the application’s specific requirements. Silicone rubber is ideal for high-temperature applications and offers excellent flexibility and durability, while natural rubber provides superior elasticity and tear resistance for general-purpose use. Both materials ensure high-quality, long-lasting components tailored to meet our clients’ diverse needs.
What is the difference between injection and compression moulding?
The key difference between injection and compression moulding lies in their process and application. Injection moulding involves melting the material and injecting it into a mould under high pressure, which is ideal for creating complex shapes with precise dimensions and fine details. Rubber compression moulding, on the other hand, places the material directly into the mould before applying heat and pressure to form the shape, making it more suitable for larger, less complex parts with slightly lower dimensional accuracy. Each method has its advantages, depending on the specific requirements of the product being manufactured.
Can you manufacture a tool with multi cavities for injection moulding?
Yes, at Keaflex, we are capable of manufacturing tools with multi cavities for injection moulding. This allows us to efficiently produce multiple parts in a single moulding cycle, significantly increasing production rates while maintaining high-quality standards. Multi-cavity tools are ideal for high-volume production runs, ensuring consistent part quality and reducing overall production costs. Our team is equipped to design and manufacture custom multi-cavity moulds tailored to meet the specific requirements of your project.
What volumes can you cater for?
At Keaflex, we specialise in accommodating a wide range of production volumes for our clients. From small batch runs for prototype development and low-volume projects to large-scale production, our state-of-the-art manufacturing capabilities and flexible processes allow us to meet diverse client needs efficiently. Whether you require a few units or thousands, we are equipped to deliver high-quality, precision-engineered components tailored to your specifications.
What are the lead times for injection rubber moulding projects?
Lead times can vary significantly depending on several factors, including the complexity of the mould design, the current production schedule, and the specific requirements of your project. Keaflex prides itself on offering efficient turnaround times without compromising the quality of the final product. To get an accurate estimate tailored to your project’s specifics, please reach out to Keaflex’s customer service team, who can provide you with the most up-to-date and relevant information.
Can you customise the material properties for specific applications?
At Keaflex, we specialise in customising material properties to perfectly match the specific requirements of your injection rubber moulding projects. Our team collaborates closely with each client, ensuring a deep understanding of every unique demand, whether it’s for specific temperature resistance, flexibility, durability, or other critical performance characteristics. Leveraging our extensive range of rubber materials and our expertise in compound formulation, we’re able to precisely tailor the rubber compounds used in the moulding process. This ensures that the final products not only meet but exceed your desired specifications.
