Various methods are utilised for the creation of rubber parts and components, such as Compression Moulding, Transfer Moulding and Injection Moulding. Today we are going to explore Rubber Injection Moulding.
Rubber injection moulding possesses its own set of advantages (and some disadvantages) but this is subject to the intended application of the part or component being produced. Additionally, it allows for the bonding of other materials, such as metal, with the rubber.
In this article, we will delve into the rubber injection moulding processes of anti-vibration mounts and other rubber engineering components;
Overview
Historically used in the manufacturing of plastic products, rubber injection moulding remains a common technique utilised in today's day and age. As the name implies, this process involves injecting compounded rubber into a closed mould. Renowned for its efficiency and speed, it is ideal for creating custom parts or bulk component production.
Procedure
Upon identifying and formulating the appropriate rubber compound for the component's purpose, a predetermined quantity of rubber (known as the shot weight) is introduced into the barrel of an injection molding press via a screw or plunger. This measured approach minimises flash or overflow which ultimately reduces the amount of waste during the overall process. The injection press is fed by a continuous supply of compounded rubber strip to continuous operation of the press.
The rubber is injected into the enclosed mold to form the desired shape. After curing, the part can be demolded, and the machine is ready for subsequent use.
Pros
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Consistent Process - Rubber injection moulding allows for precise control over the injection process, resulting in consistent control of dimensions and characteristics. This ensures that each part meets the required specifications and reduces variability from batch to batch.
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Rapid process - Injection Rubber moulding process eliminates the need for pre-forming rubber into individual blanks and the heat press can be reused as soon as the previous component has been demoulded, allowing for a higher output capacity compared to other moulding techniques.
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Design Flexibility - Manufacturers have the flexibility to produce parts with varying complexities and geometries. This method enables the production of intricate designs and complex shapes that may be challenging to achieve with other manufacturing processes.
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Multi-cavity molds - Utilising sprues enables a single mould to provide multiple cavities, allowing for the production of multiple parts per shot.
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Minimal waste - The closed mould design significantly reduces flash, minimising material wastage, and provides a cleaner end product.
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Ideal for high-volume production - Its efficiency makes it suitable for mass-producing parts.
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Material Variety - Rubber injection moulding supports a wide range of materials, including different types of rubber compounds. This versatility allows users to choose the most suitable material for their specific application requirements, whether it's for durability, flexibility, temperature resistance, or other properties.
Cons
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Potential higher cost - For low-volume production, rubber injection moulding may incur greater expenses compared to alternative methods, due to initial set up costs.
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Material Waste - While this process is generally efficient in terms of material usage, there can still be some waste associated with trimming excess material (flash) from finished parts.
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Limited Material Compatibility - Although rubber injection moulding supports a wide range of materials, certain specialised elastomers or additives may be challenging to process or may require specific equipment configurations. This limitation could restrict material options for certain applications.
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High Tooling Costs - Rubber Injection Tools (moulds) are significantly more expensive than compression and transfer moulds. They are therefore suited to high volume production runs.
Rubber Moulding with AV Industrial Products Ltd
At AV Industrial Products Ltd, rubber injection moulding plays an important role in our production process. Collaborating with clients, we determine the most suitable rubber compound for their applications and the best manufacturing method for the production application.
For further insights into utilising rubber for effective anti-vibration solutions, visit our blog section. To inquire about purchasing rubber parts, please don't hesitate to contact us today.
