Kea-flex's Technical Services

Yes, at Keaflex, we are equipped to design and engineer drawings for parts. We offer a comprehensive in-house design facility that can handle both simple and complex moulds, special-purpose tooling, jigs, and fixtures. We utilise fully integrated 2D and 3D modelling CAD/CAM software, which is directly linked to our machining centres, allowing us to efficiently create accurate tooling and part designs. This service facilitates the rapid development of prototypes and the efficient transition to full production, ensuring that we meet our clients’ specific requirements effectively. For more information or to discuss specific requirements, contact us directly.

Our design process begins with a detailed consultation to fully understand your project needs. We then move into the conceptual design phase using advanced CAD software to create initial sketches and 3D models. This is followed by detailed design work, which may include simulations to optimise the tool and part design. Prototyping is the next step, allowing us to test the design in real-world conditions and make necessary adjustments. Finally, we finalise the design based on prototype testing and proceed to full-scale production. Throughout each phase, we maintain close communication with you to ensure the final product meets all specifications and quality expectations. This streamlined process ensures efficiency, cost-effectiveness, and high-quality outcomes tailored to your specifications. For more details on how we can assist with your design needs, please contact us directly.

Selecting the appropriate materials and defining tolerances for rubber moulding projects involves a meticulous process to ensure each component meets the required specifications and performance standards. Our material selection process starts with understanding the application’s specific needs, including environmental conditions, mechanical stresses, and chemical exposures. We work with a wide range of materials, from natural rubber to advanced synthetic elastomers like silicone to match the perfect material to the application’s requirements.

For defining tolerances, we rely on industry standards and our extensive experience in rubber moulding to set precise dimensional limits that ensure functional fit and performance. Our engineering team uses state-of-the-art CAD/CAM technology to design moulds that adhere to these tolerances, alongside advanced manufacturing techniques that help maintain consistency throughout the production run. This comprehensive approach allows us to provide robust solutions tailored to our client’s needs, ensuring high-quality results and reliability in the final products. For more information on our material selection process and how we define tolerances, please contact us directly.

At Keaflex, we select the best materials for our rubber moulding tools based on their performance requirements and the specific needs of each project. We commonly use high-grade steel for its durability and wear resistance, ideal for high-volume production. Aluminium is preferred for its excellent thermal conductivity and quick machining capabilities, making it perfect for prototypes and small runs. For less intensive uses, pre-hardened steels offer a good mix of durability and ease of machining. Each material is chosen to optimise the balance between mechanical properties, cost, and the complexity of the parts we are moulding, ensuring the best outcomes for our clients’ projects.

The typical lifespan of rubber moulding tools varies widely based on several factors, including the material used for the tool, the complexity and frequency of its use, and how well it is maintained. Tools made from high-grade steels, for instance, are durable and can last for hundreds of thousands of cycles, especially when they are well-maintained and operated under optimal conditions. On the other hand, tools made from softer materials like aluminium may have a shorter lifespan but are more cost-effective for short runs or prototyping. For high-volume production, tools may need to be made from more durable materials to withstand the rigours of continuous use without significant wear. Proper maintenance such as regular cleaning, inspections, and repairs can significantly extend the life of a moulding tool. Factors like the design of the tool, the type of rubber being moulded, and specific processing conditions (e.g., temperature and pressure used) also critically influence tool longevity.

In practice, tool life can range from tens of thousands to over a million cycles, depending on these factors. At Keaflex, we provide detailed guidelines and support to ensure that tools are designed optimally and maintained properly to maximise their lifespan, adapting our approaches based on the specific needs and conditions of each project.

When designing tooling for different types of rubber, several unique properties of each rubber must be considered to ensure optimal functionality and longevity of the tools. Different rubbers vary in their thermal properties, requiring specific temperature controls and cooling times during the moulding process. The tooling material itself needs to be chosen for its resistance to abrasion and potential chemical interactions with the rubber, such as the oil resistance required when working with nitrile rubber. Elasticity and hardness of the rubber also dictate the flexibility and robustness of the tool design; softer rubbers need gentle handling to avoid tearing, while harder rubbers require stronger tools to achieve precise shapes. Additionally, some rubbers may adhere to the mould, necessitating special surface treatments or release agents to facilitate easier demoulding. Lastly, rubbers like liquid silicone rubber (LSR) that undergo unique curing processes might require specialised tool designs to accommodate their specific handling and curing characteristics. At Keaflex, we integrate these considerations into our tooling design process, customising each tool to meet the demands of the rubber material used, thereby enhancing both production efficiency and product quality.