Category: Silicone Rubber

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Rubber Mouldings: What They Are and How They Are Made

Rubber Mouldings

Rubber mouldings are an essential component in many industries, from automotive to construction. These mouldings are used for sealing, cushioning, insulating, and protecting various components, including windows, doors, and electrical systems. They come in different shapes and sizes, and they can be custom-made to fit specific applications.

In this article, we will explore what rubber mouldings are, how they are made, and the different types of rubber used in their production. We will also discuss the benefits and their applications in different industries.

What are Rubber Mouldings?

Components made of rubber that are used to seal, cushion, insulate, and protect different components. They are made by pouring liquid rubber into a mould that has the desired shape and allowing it to cure. Once the rubber has cured, it is removed from the mould, and any excess material is trimmed off.

Rubber mouldings can be made from different types of rubber, including natural rubber, synthetic rubber, and silicone rubber. The type of rubber used depends on the intended application, as each type of rubber has its unique properties.

How are Mouldings Made?

The production of rubber mouldings involves several steps, including mould design, material selection, mixing, moulding, and finishing.

Mould Design: The first step in the production of rubber mouldings is the design of the mould. The mould is designed based on the desired shape and size of the moulding.

Material Selection: The next step is the selection of the appropriate rubber material. The type of rubber used depends on the intended application, as each type of rubber has its unique properties.

Mixing: The rubber material is then mixed with various additives, such as accelerators, curing agents, and fillers, to improve its properties and performance.

Moulding: The mixed rubber material is then poured into the mould, and the mould is closed. The rubber is then allowed to cure, and the mould is opened to remove the finished rubber moulding.

Finishing: The finished rubber moulding is then inspected for quality, and any excess material is trimmed off. The rubber moulding may also be treated with a surface coating to improve its appearance and performance.

Types of Rubber Used in Rubber Mouldings

Rubber mouldings can be made from different types of rubber, depending on the intended application. The most common types of rubber used in rubber mouldings include:

  1. Natural Rubber: Natural rubber is made from the sap of rubber trees and is known for its excellent elasticity and resilience. It is commonly used in applications that require high tear and abrasion resistance, such as in the automotive industry.
  2. Synthetic Rubber: Synthetic rubber is made from petroleum-based chemicals and is known for its excellent chemical and weather resistance. It is commonly used in applications that require high temperature and chemical resistance, such as in the aerospace industry.
  3. Silicone Rubber: Silicone rubber is a synthetic rubber made from silicone and is known for its excellent heat and cold resistance. It is commonly used in applications that require high-temperature resistance, such as in the food and beverage industry.

Benefits

Rubber mouldings offer several benefits, including:

  1. Seal: Rubber mouldings are used to create a tight seal around components, preventing the entry of dirt, moisture, and other contaminants.
  2. Cushion: Rubber mouldings are used to cushion components, preventing damage from impact and vibration.
  3. Insulate: Rubber mouldings are used to insulate components, protecting them from heat, cold, and electrical currents.
  4. Protect: Rubber mouldings are used to protect components from damage, prolonging their lifespan and reducing maintenance costs.

Applications

Rubber mouldings are used in a wide range of industries and applications, including:

  1. Automotive: In the automotive industry to seal doors, windows, and trunks, insulate electrical systems, and cushion components.
  2. Construction: Rubber mouldings are used in the construction industry to seal windows and doors, insulate buildings, and protect components from weather and environmental factors.
  3. Aerospace: Used in the aerospace industry to seal aircraft windows and doors, insulate components, and protect against extreme temperatures and pressures.
  4. Medical: In the medical industry to create seals and gaskets for medical devices and equipment.
  5. Food and Beverage: They’re used in the food and beverage industry to create seals and gaskets for food processing equipment and containers.

Conclusion

Flexible mouldings are an essential component in many industries, providing sealing, cushioning, insulation, and protection to various components. They are made by pouring liquid rubber into a mould that has the desired shape and allowing it to cure. They can be made from different types of rubber, including natural rubber, synthetic rubber, and silicone rubber, depending on the intended application. They offer several benefits, including sealing, cushioning, insulation, and protection, and are used in industries such as automotive, construction, aerospace, medical, and food and beverage. By understanding the different types of rubber mouldings and their applications, you can choose the best for your specific needs.

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Silicone End Caps: A Guide for Industrial and DIY Use

Silicone End Caps

If you have ever worked with electronics, you must have encountered a situation where you need to cover the exposed ends of a wire or a pipe. That’s where silicone caps come in handy. These versatile tools can be used in a variety of industrial and DIY applications, from electrical insulation to sealing pipes and tubes. In this article, we will take a comprehensive look at silicone end caps, their properties, types, and applications.

What are Silicone Rubber End Caps?

Silicone rubber caps are small, flexible covers. They are designed to fit snugly over the end of a wire, tube, or pipe and provide a protective barrier. Silicone is an excellent material for making end caps because of its unique properties. It is durable, heat-resistant, and flexible, which allows it to conform to the shape of the object it is covering. Moreover, silicone is non-reactive and non-toxic, making it safe to use in various industrial and medical applications.

Types of Silicone End Caps

Silicone caps come in various types and sizes, each designed for specific applications. Here are some of the most common types:

Tapered End Caps

Tapered end caps have a conical shape and are used to seal pipes, rods, and tubes of different diameters. They have a thick base that provides a secure fit and a tapered tip that allows easy insertion.

Flat End Caps

Flat end caps have a flat surface and are used to cover the ends of wires, cables, and connectors. They come in different sizes and are available with or without a hole in the center.

Threaded End Caps

Threaded end caps have internal or external threads and are used to seal threaded pipes and fittings. They come in different thread sizes and materials to match the specific application.

High-Temperature End Caps

High-temperature end caps are designed to withstand extreme temperatures and are used in high-temperature applications such as furnaces, ovens, and industrial machinery.

Medical-Grade End Caps

Medical-grade end caps are made of high-quality silicone rubber and are designed for medical and pharmaceutical applications. They are non-reactive, non-toxic, and can withstand sterilization.

Properties of Silicone Rubber Caps

Silicone rubber caps have several unique properties that make them ideal for various applications. Here are some of the most notable properties:

Heat Resistance

Silicone end caps can withstand high temperatures, making them ideal for use in industrial and high-temperature applications.

Electrical Insulation

Silicone caps provide excellent electrical insulation and can withstand high voltage and current.

Flexibility

Silicone caps are highly flexible and can conform to the shape of the object they are covering, ensuring a secure fit.

Weather Resistance

Silicone rubber is highly resistant to weathering, UV rays, and ozone, making them ideal for outdoor applications.

Applications of Silicone End Caps

Silicone rubber caps have a wide range of applications in various industries. Here are some of the most common applications of silicone end caps:

Electrical Insulation

Silicone end caps are used to provide electrical insulation for wires, cables, and connectors. They can withstand high voltage and current and can prevent electrical shorts and sparks.

Sealing and Protection

Silicone end caps are used to seal and protect pipes, tubes, and fittings from dust, moisture, and other contaminants. They can also prevent leaks and corrosion.

Medical and Pharmaceutical

Silicone caps are used in medical and pharmaceutical applications to seal and protect medical devices, containers, and packaging from contamination and damage. They are used in a variety of medical devices, including catheters, needles, and surgical instruments.

Automotive

Silicone caps are used in the automotive industry to seal and protect electrical connectors and wires. They can withstand high temperatures, chemicals, and vibrations, making them ideal for use in engine compartments.

Aerospace

Silicone rubber caps are used in the aerospace industry to seal and protect electrical connectors and wiring harnesses. They can withstand extreme temperatures and harsh environments, ensuring the safety and reliability of critical aircraft systems.

DIY and Home Improvement

Silicone rubber caps are also popular among DIY enthusiasts and homeowners. They can be used to cover the ends of exposed wires and cables, seal pipes and tubes, and protect furniture and floors from scratches.

How to Choose the Right Silicone End Caps?

Choosing the right silicone end caps depends on several factors, including the type and size of the object you want to cover, the application, and the environment. Here are some tips on how to choose the right silicone end caps:

Consider the Size and Shape

Choose the caps that fit snugly over the object you want to cover. Tapered end caps are ideal for pipes and tubes of different diameters, while flat end caps are suitable for covering the ends of wires and cables.

Consider the Temperature Range

Choose the caps that can withstand the temperature range of your application. High-temperature end caps are ideal for use in extreme temperatures, while standard end caps are suitable for moderate temperatures.

Consider the Chemical Resistance

Choose the end caps that are resistant to the chemicals and solvents present in your application. Medical-grade end caps are highly resistant to chemicals and are ideal for medical and pharmaceutical applications.

Consider the Environmental Factors

Choose the silicone caps that can withstand the environmental factors present in your application. Weather-resistant end caps are ideal for outdoor applications, while ozone-resistant end caps are suitable for environments with high ozone levels.

How to Install Silicone End Caps?

Installing caps is a simple process that requires no special tools or equipment. Here are the general steps to follow:

  1. Clean the object you want to cover with a solvent or alcohol to remove any contaminants.
  2. Choose the appropriate cap and ensure that it fits snugly over the object.
  3. Insert the end cap over the object, ensuring a tight fit.
  4. If necessary, secure the end cap with a zip tie or clamp to prevent it from falling off.

Conclusion

Silicone end caps are versatile tools that can be used in various industrial and DIY applications. They provide excellent protection and insulation for wires, cables, pipes, and tubes and can withstand extreme temperatures, chemicals, and environmental factors. Choosing the right silicone end caps depends on several factors, including the size, shape, temperature range, and environment of your application. With the right silicone end caps and proper installation, you can ensure the safety, reliability, and longevity of your equipment and devices.

FAQs

  1. Are silicone end caps reusable?

Yes, silicone caps are reusable and can be used multiple times.

  1. Can silicone end caps withstand high voltage and current?

Yes, silicone caps provide excellent electrical insulation and can withstand high voltage and current.

  1. Are silicone caps safe for medical and pharmaceutical applications?

Yes, medical-grade caps are non-reactive, non-toxic, and can withstand sterilization, making them safe for medical and pharmaceutical applications.

  1. Can silicone end caps withstand extreme temperatures?

Yes, high-temperature silicone rubber caps are designed to withstand extreme temperatures and can be used in high-temperature applications.

  1. Can silicone caps be used for outdoor applications?

Yes, weather-resistant silicone caps are highly resistant to weathering, UV rays, and ozone, making them ideal for outdoor applications.

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Specialist bespoke metal fabrication requires specialist bespoke silicone rubber mouldings

Bespoke rubber mouldings for masking and other applications in low volume  fabrications.

There are thousands of companies producing low volume metal fabrications for specialist applications in vehicles. This isn’t just specific to motor vehicles either. The UK is not only a leading exported of motor vehicles but also aerospace, defence, shipping and other modes of transport. Trains are also produced in the UK.

The UK has always been famous for pioneering design and bespoke solutions. Whether its military conversions on vehicles, emergency vehicles or any other short production run such as motorsport, the UK is world renowned for design and bespoke manufacturing.

For manufacturers and sub contractors, the processes on short production runs can be very similar to large volume production. The main difference being that the big robotic production lines aren’t often used in low volume manufacturing, but that in its self is why the UK is so different. There are thousands of small engineering firms across the UK producing bespoke assemblies for defence, aerospace, motorsport and specialist vehicles.

By the very nature of bespoke and limited run, masking can also take on a need for bespoke applications. AFAC has over the years produced a wide variety of custom silicone rubber mouldings for these niche industries.

Case study of bespoke silicone rubber mouldings for low volume metal fabrication work

For one customer, when the military were still using Land Rovers as a principle vehicle, they were installing a radio rack into the rear of the vehicle. It was a simple design of a plate with oval holes reamed out of it to allow adjustment of the radio.

The problem was that the bolts and washers used to fix the radio to the plate were also the earthing points. As a result, an area around each oval hole needed masking to allow for the movement that had been built into the design.

Using the BAKEWELL Silicone Rubber TUGPLUG as a basis for the design, we created an oval section and then added a “washer” into the design with a sealing lip around the edge for quality of finish. The first design was prototyped and worked perfectly.

Tooling is relatively inexpensive and the production run was only a matter of a few hundred items.

The Outcome

Satisfied customer and problem solved.

Working on limited volume fabrications and have a need for custom rubber mouldings or extrusions? Get in touch right now on 0845 094 0522

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What’s different about rubber moulding and rubber extrusion?

What’s the difference between a moulding and an extrusion?

The differences between rubber moulding and rubber extrusion are really simple. The are different manufacturing methods for producing shaped rubber components.

The easiest way to know the difference between extrusions and mouldings is simple.

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Rubber extrusions

Extrusions are moulded items such as tubes which can be produced in endless lengths. Extrusion involves forcing uncured rubber through a shaped tool and curing immediately afterwards. Extruding rubber is like turning a tap on that produces whatever 2 dimensional profile you require in continuous length.

Tubing is by far the most common type of extrusion but extrusions are commonly found in seals and

Shop for extrusions

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Rubber Mouldings

Mouldings are the opposite. Mouldings are 3 dimensional shapes. Mouldings are produced by forcing uncured rubber into a mould with no exit. The mould is then emptied and the cycle repeated. Mouldings are always numbers of parts produced.

Plugs, caps, o-rings, seals & gaskets are more common mouldings used in industrial applications.

Shop for mouldings

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What is Silicone Rubber

What is Silicone Rubber and what is it used for?

 

What is silicone rubber?

Silicone Rubber is a high performance inorganic elastomer. Its characteristics mechanically and chemically are unmatched by organic elastomers.

The unique properties of silicone rubber make it a top choice for an enormous variety of applications in industrial and consumer markets From mobile phone covers to industrial powder coating ovens, silicone rubber has is used for producing huge quantities of product.

Properties of silicone rubber

Silicone rubber can withstand extremes of temperature and is extremely flexible. It can be moulded or extruded and is transparent in its natural state. It can be dyed solid colours and mixes of colour.

Types of silicone rubber

Industrial Grade

By far the most common type of silicone rubber, industrial grade silicone rubber is commonly available and suits any industrial application not involving food or laboratory environments.

Food

More commonly used for consumer applications, food grade silicone is safe for all applications where contact with the mouth, food or children may be a consideration. It’s more costly than industrial grade silicone rubber.

Medical

Medical grade silicone rubber is produced for laboratory and “cleanroom” environments. The most costly of the 3 types listed, medical grade components are supplied free of any dust or swarf produced as a bi-product of the manufacturing process. Curing is slightly different with Medical grade silicone rubber too leading to increased cost.

 

Benefits of silicone rubber

 

  • Silicone rubber lasts longer in more extreme conditions
  • Weather has little effect — Silicone rubber stands up to the environment whatever the conditions, sun, snow, rain, it maintains its properties
    • The environment can affect organic elastomers causing them to deteriorate performance
  • Withstands extremes of temperature — from -100 to 316ºC (-148 to 600ºF)
    • Deterioration is caused at lower temperatures with organic elastomers >100ºC (>212ºF); performance can also be hindered by rigidity <-25ºC (<-13ºF)
  • You have plenty of choices
    • Broad hardness range (from 10 to 80 Shore A),
    • Useful range of color choices (from transparent to brightly colored)
  • Improves performance of seals and fittings
  • High performance electrical insulation characteristics.
    • Relatively unchanged with exposure to harsher conditions (heat, cold, moisture, oil, ozone, UV rays)
  • Remains flexible and resilient across a broader temperature scale
  • Improves the way consumer goods look and feel
  • Inert (no taste or smell); many food-contact options

 

Is Silicone Rubber the material for you?  Call us on 0845 094 0993 to speak to one of our experts today or click here to find out more.

 

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Creating bespoke silicone rubber moulding for manufacturing case study

Bespoke Silicone Rubber Moulding

Case Study: Creating a bespoke silicone rubber moulding to speed up manufacturing

Sometimes, when a client comes to us with a unique problem that needs solving, we create a bespoke silicone rubber moulding for them. Then, having created a solution to the problem, we realise that there may be other customers facing the same problem. The result? A new product line available to all our clients.

This scenario is precisely what happened when we were approached by an international client who had a finishing problem. The company in question is a leader in secondary power distribution solutions with an outstanding pedigree. The business specialises in high-performance medium voltage switchgear for industrial, utility and commercial applications. Incredibly, they have more than 100 years’ experience in enabling the safe and reliable distribution of energy all over the world.

The problem they consulted us about was this: they were looking for a cap that would protect the threaded ends of studs during media blasting to remove oxides and scale from their steel assembly. The cap would also need to act as a mask during electro-static powder coating. However, the caps they were using couldn’t withstand the punishment of shot blasting.

It was time for the AFAC team to step in. We designed a beefed-up version of the T-Cap. It has heavier walls and it doesn’t have the lip feature that the standard caps have. The reason for omitting this is that the blasting process is so fierce it tends to blast the cap completely off the stud. The resulting design for the new cap has increased wall thickness, no lip and a modified top flange to withstand the strain of being pulled off. As an extra precaution, the bore of the cap has also been reduced to give an increased friction fit—a further measure to help it remain in place during blasting.

The result was a winner! The new cap is able to withstand the rigours of blasting and the customer has requested a range of similar caps to use with different sizes and lengths of studs. These robust caps are now also available to our other customers. So one client’s problem resulted in all our clients gaining a new product!

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Manufacturing using 3D Printing – Roll on the Revolution!

How will manufacturers benefit from 3d printing?

Most of us have known about the advent of 3D printing for a while now. But what the inventors haven’t so far been able to show us is how its application is going to revolutionise certain industrial manufacturing processes. However, forward thinking businesses, such as AFAC, are starting to explore its potential—and now that it’s possible to 3D print in rubber, we can see a great future ahead!

3D printing – what is it and how does it work?

If you’ve seen a 3D printer at work, it’s an extraordinary sight to behold. A template in the form of a computer generated .cad file gives the printer its template. Press ‘PRINT’, and a stream of plasticising powder is fused with a bonding element to form a 3D plastic reproduction of the template. Furthermore, the technology has the ability to recreate complex objects, complete with moving parts—and all to an incredible degree of accuracy. But it’s not just plastic creations that can issue forth from the latest 3D printers. New printers have been unveiled that can create complicated multi-coloured sweets from sugar and chocolate. Just what the world has been waiting for!

To see an amazing 3D print out, take a look at this QI clip.

New 3D printing applications in manufacturing

However, more useful applications might not have the novelty value of spun sugar but they may revolutionise manufacturing as we know it. For AFAC, the eureka moment came when Ryan Mullins discovered that 3D printing in rubber is also available.

Rubber? What’s the big deal?

To date, most 3D printing has used plastic. For AFAC, plastic prototypes are not ideal for demonstrating a wide range of products which are generally made from rubber. The rigid nature of plastic doesn’t adequately show how the rubber and silicone plugs and covers will perform.

However, using a 3D printer to create rubber prototypes represents a game-changer for two reasons:

  • For AFAC, the properties of rubber are an integral aspect to the product design and effectiveness of proving concept for the vast majority of its products. In future, we will be able to utilise 3D rubber printing to produce rubber items with varying shore values as a way to provide the fastest and most efficient prototyping service for our clients. Lead times in bespoke product development will be slashed.
  • As 3D printing technology advances, costs will fall and its use will become widespread in all areas of mass production. 3D printing in rubber will reduce the cost of custom mouldings production. Tooling costs will exchanged for cheaper printer set-up charges and bespoke rubber prototypes will become available overnight. We’re not there yet, but with advances in the technology to increase the variety of materials and colours available, we will be soon.

3D Printing for designers and product development

For product designers and developers, this represents a massive leap forward. It’s conceivable that one could move from idea to full production in just a matter of hours. And with your own in-house 3D printing facilities, fears about product protection and pirating simply evaporate.

The UK has built its reputation on the extraordinary skill of its niche designers and product developers. 3D printing will hopefully allow more of the subsequent manufacturing to be based once again on British soil. And hopefully, AFAC will be one of the companies leading the way.

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UK Inventors of the BAKEWELL Silicone Rubber Powder Coating Plug

Inventing the BAKEWELL Silicone Rubber Powder Coating Plug

It may be a cliché that need is the mother of invention but, in the case of the Bakewell Silicone Rubber Powder Coating Plug, it’s certainly true. As powder coating took over from wet paint spraying in the early 80s, a new need was identified. AFAC, or Applied Fastenings and Components as the company was then known, devised the perfect solution – The Bakewell SIlicone Rubber Powder Coating Plug—and it’s still selling strongly to this day!

Back then, the company’s business mainstay was supplying fasteners to sheet metal workers. If a customer required a female thread, either a weld nut, rivet bush or self-clinching nut would be supplied. Once assembled, these solutions provided a far stronger captive thread than simply tapping a hole through the sheet metal.

Happy clients all round? Well, no! There was still an issue. Sheet metal components tend to need protection from oxidization. In other words, they are painted, plated or given an electro-static powder coating. The problem with this is that exposed threads can become contaminated by the coating process, leaving them unfit for purpose when it comes to the final assembly.

AFAC had already solved this problem with regard to male threaded studs, so it was natural we should start casting around for a way of protecting the female threads. The existing solution of using PVC tapered plugs was fine for wet painting—but they couldn’t take the heat generated during powder coating. Diligent research suggested there was a material that would be just perfect for the job—silicone rubber. Able to withstand temperatures of up to 315°C while remaining flexible, it made the perfect solution for thread masking.

Careful thought went into the design of the new plug. Tapered in shape, it had a cylindrical head for easy handling. It was trialled in a range of sizes to ensure it sealed the thread, while leaving approximately one third of the plug out of the hole. This allowed electro-static attraction to draw the powder under the cylindrical head to cover the component right to the very edge of the hole. With generous help from a local powder coater, the new plug was tested and declared a success!

The Bakewell Silicone Rubber powder coating Plug has now been in production for over 30 years, in a range of colour coded sizes, and it continues to be an invaluable masking tool for all powder-coating operations. It’s the original hole-masking solution—devised and designed by AFAC!

 

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Solving customer problems with bespoke design and production of silicone rubber mouldings.

The Problem

When one of our customers, manufacturing parts for a military vehicle, had a masking problem, they called on A.F.A.C.’s technical team to help them out. The problem they had was with a bracket that supported military radio equipment. Continue reading Solving customer problems with bespoke design and production of silicone rubber mouldings.