What Is Lsr Liquid Silicone?
lsr liquid silicone that elaborately produced by Fox Mold (Dongguan)Co., Ltd. is bound to have a bright application prospect in the industry. The product is a complete and integrated concept that provides a full range of practical solutions for customers. Through the dedicated effort of our design team in analyzing market demand for the product, the product is eventually designed with an aesthetically pleasing appearance and functionality that customers want.
Fox Mold enjoys high popularity across the world. All the products under the brand are of superior performance, bringing a fantastic user experience. Thanks to that, the products help safeguard and consolidate the brand fame and further increase the brand value. More and more customers speak highly of the products and give thumbs-up on our social media like Facebook. Those compliments also attract new customers to choose us as their reliable partner.
We can match your current design specification or custom-design new packaging for you. Either way, our world-class design team will review your needs and suggest realistic options, taking into consideration your time frame and budget. Over the years we have invested heavily in state-of-the-art technology and equipment, enabling us to produce samples of products at with ultimate quality and precision in-house.
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Part special feature: There are two plastic raw material and metal limiting stopper assembled, hard plastic is PPO+GF30, soft plastic is liquid silicone rubber.
Our customers are often faced with a challenge: how to over molding liquid silicone rubber parts with hard plastic with glass fiber, but ensuring the bonding is good, will not separate with heat or other extremely condition.
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The second tough requirement is that how to make this liquid silicone geometry without any flash or make sure the flash size is within tolerance？
These LSR over molding parts are critical in Energy saving system and EV fields. But realizing them is difficult.
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Our innovative mold technology solves this problem by fitting two molds after each mold testing.
Not only that, but its unique processing also ensure no flash on parts or flash is kept within tolerance.
If you want to know more, click the link below or visit our official website and don't forget to subscribe to our channel for more updates.
The injection molding process mainly employs thermoplastic and thermosetting materials. The preferred thermosetting material for molding is LSR. It can produce flexible, and shockproof parts, exhibiting high-temperature tolerance. Liquid silicone Rubber(LSR) injection molding is a fabrication technique through which raw, unfixed silicone rubber is converted to fully functional and rigid parts. These products are optimally used in gaskets, kitchen utensils, and over-molded components.
This guide presents information about the LSR injection molding process. In addition, it provides the process steps involved, the applications, primary benefits, and design considerations. Let’s explore further!
What Is LSR Injection Molding?
Liquid silicone rubber (LSR), is a high-purity cured silicone rubber. It’s a chemically stable thermosetting polymer that has desirable features such as biocompatibility, chemical and water resistance, high compression rates, fire, and heat resistance up to 250 °C.
The molding process used to injection mold LSR is referred to as liquid silicone rubber molding. LSR molding is comparatively distinct from regular injection molding equipment. It comprises a metering pump that pumps the two liquids; a catalyst and the base silicone separately. Further, it mixes them before feeding into the pre-defined mold.
In operation, the mold cavity is subjected to heating to cause silicon vulcanization. Moreover, LSR is a thermoset material and to solidify the material to bring it into the network of polymer chains, heat is crucial. LSR is produced through the injection molding process, in which a low-viscosity two-component compound is mixed and heat-cured in a mold with the help of a platinum catalyst to form a functional LSR part.
How Does Liquid Silicone Rubber Injection Molding Work?
The process steps of Liquid Silicone Rubber Injection Molding are given below;
▶Step 01: Tool Creation:
The mold is developed and produced through kinds of machining process to meet the requirements of high-temperature usage for the LSR process.
▶Step 02: Material Preparation
Two components are prepared: the base silicone substance and the platinum catalyzer. These materials are stored in different tanks but for measurement purposes, they are connected to a meterage system.
▶Step 03: Mixing Components
The base silicone and catalyst are pumped in a precise 1:1 through a static or dynamic mixer. This ensures a well-mixed and homogeneous compound.
▶Step 04: Injection into Mold
The mixed LSR is heated and high-pressure injected into the mold cavity of the detailed member features.
▶Step 05: Curing Process
The mold is heated to cause the cross-linking of the silicone. So, helps form a rigid part with the desired characteristics.
▶Step 06: Cooling and Demolding
Once set the molds are cooled and then they are taken apart very slowly to free the molded parts. This may be done manually or with the help of automated systems.
▶Step 07: Post-Molding Operations
Subsequent operations may be required after demolding is accomplished. These are slitting, printing, marking, assembling, and post-curing to give the final shape to the products.
Comparing LSR Injection To Convention Injection Molding
Here’s a comparison table including technical details related to comparing LSR Injection Molding to conventional molding techniques:
Industrial Applications of LSR Injection Molding
Liquid silicone rubber (LSR) injection molding is a highly adaptable process used across various manufacturing industries:
●Medical and Healthcare
Biocompatibility is one of LSR’s most outstanding properties to makes it compatible with medicine. It is soft and flexible and enables the skin to be in contact with for a long without any danger. Some common uses include seals gaskets and surgical instruments. Moreover, several applications are made of injection molded parts such as drug delivery systems and catheters, respiratory masks, and medical equipment enclosures.
●Automotive Industry
LSR’s thermal stability is advantageous in the automotive industry. It is heat resistant around the engine and other parts. LSR molding products are used in seals, connectors, and electronic covering. Moreover, these are exploited in windshield wiper blades because it does not scratch the plastic used in the wiper blades. These blades last longer than other rubber blades.
●Electronics
Due to its electrical insulation characteristics, electronic sectors heavily use LSR. Some common products included; keypads, buttons, watertight gaskets, and many more. It also supplies seals and connectors for different devices.
●Consumer Products
LSR molding is highly used in manufacturing kitchenware and toys. Pacifiers, infant bottles, and wristwatches for example are some of the products usually made by silicone injection molding. These attributes further contribute to consumer good appeal because of the flexibility and easy-to-clean design.
Overall, LSR molding has several advantages. Even though the process may involve the use of special equipment. Because of its outstanding compression set, it is invaluable to various sectors. Such products include silicone medical implants and drug-delivery devices. Other include hearing aid tips, shower heads, and protective covers. LSR is also proficient in developing thermal stable parts for automotive, and aircraft use.
Advantages & Disadvantages of LSR Injection Molding
Here are the primary benefits and drawbacks of liquid silicone rubber injection molding;
● High Biocompatibility: LSR is nonirritant and can be used where skin contact may be prolonged. Therefore, it is well suitable for the medical field.
● Good Thermal Stability: LSR has high heat resistance and can operate in temperature conditions that reach 250 °C.
● Precision Tolerances: Silicone injection molding delivers dimensional control within ±0.01 mm to ±0.05 mm for complex geometries.
● Durability and Longevity: LSR compound has high chemical stability and keeps its properties for a long time. Moreover, these products cannot be degraded by UV light.
● Multiple Design Options: The molding process also permits intricate shapes and different surface coatings; thus, increasing the possibilities of design.
As you know, no process or material is perfect, and LSR injection molding has its flaws.
● Higher Initial Costs: LSR molding setup needs certain equipment which raises the initial process cost than conventional molding processes.
● Longer Cycle Times: LSR molding cycles are typically longer than in conventional thermoplastics, 30-60 seconds as opposed to 15-30 seconds.
● Limited Material Choices: However, it has different properties than other thermoplastics. So, fewer materials can be combined with LSR. In addition, the complexity of the processing requirements of these biobanks becomes apparent.
● Problems Related To High Production Quantities: LSR injection molding requires higher setup costs and longer cycles making the technique less efficient when it comes to large volumes of production.
Materials Compatible For LSR Injection Molding
Here’s a table listing materials compatible with LSR molding along with their applications:
Material
Applications
Liquid Silicone Rubber (LSR)
Medical devices (catheters, seals, surgical instruments)
Platinum-Cured Silicone
Food-grade kitchenware (molds, baking mats)
Silicone Elastomers
Automotive parts (gaskets, seals, wiper blades)
High-Temperature Silicone
Electronics (keypads, switches, connectors)
Colored Silicones
Consumer products (toys, wristbands, baby products)
Flame-Retardant Silicone
Industrial applications (grommets, strain relief devices)
UV-Stabilized Silicone
Outdoor products (shower heads, garden equipment)
Conductive Silicone
Electronic components (sensors, conductive pads)
Design Considerations for LSR Injection Molding
Several design and manufacturing factors are critical to successful LSR injection molding. Below are critical aspects to keep in mind:
✔Part Design Guidelines
It’s crucial to design the components to be molded in LSR molding differently from thermoplastic molding techniques. Interestingly, silicone parts are recognized for their simpler design requirements.
● Electability: The mentioned flexibility of silicone ensures easy removal from the molds. The ejection pin layout is not a fundamental design consideration. As parts can typically be pulled out of a mold manually. It has the benefit of permitting more free draft angles.
● Wall Thickness Variation: LSR’s ability to be shear thinning means that fewer parts need to be made with uniform wall thicknesses because the material can flow. As a result, silicone parts can be designed to be thicker than thermoplastic parts.
● Protruding Undercuts: LSR can deal with protruding undercut features because this material is rather flexible and the parts with such features can be easily extracted without the usage of additional side-action mechanisms.
● Sealing Requirements: As LSR has a low viscosity, it can seep out through the parting line if not well closed. Tooling seals must fit, and be enclosed well to minimize material loss.
✔General Design Rules
● Parting Lines: Parting phrases should be brief as a way of reducing the flash impact.
● Draft Angles: For shallow parts, no draft may be required; otherwise try for one degree of draft per 2.5 cm.
● Gate Placement: Mount position gates at the bottom of the least obvious places to retain design.
✔Metering and Mixing Process
Unlike thermoplastic or plastic injection molding, LSR injection employs two components: An organ polysiloxane base silicone and a platinum catalyst. These materials are delivered in a fixed proportion through a metering unit and combined with a static or dynamic mixer.
✔Other Manufacturing Factors
● Bonding Support: Make sure the process and mold design allow for good adhesion between the substrate and LSR.
● Dimension Variability: The thickness of the winding can vary due to the curing and material shrinkage therefore shade allowances should be made based on these conditions. It is advised to consult the mold designers to get the correct dimensions.
● Draft Angles and Undercuts: It’s recommended to design the parts with the correct draft angles and minimize the undercuts to ease the ejection process.
● Surface Texture Selection: Select the right textures for the silicone parts that will meet the functional aspects, as well as the aesthetic aspects.
● Optimal Mold Design: The mold design features of gate locations, vents, and cooling system should be well optimized to increase the part quality and decrease the cycle time.
Conclusion
Liquid silicone rubber injection molding is versatile and economical. It provides more efficient manufacturing benefits than the other molding techniques. The process is optimal for complex designs with high dimensional accuracy throughout. Moreover, It’s adaptable and has become indispensable for different fields and companies. Automotive, Aerospace, and electronic sectors are the primary consumers of LSR injection molded products.
Affordable Custom LSR Molding Services at Fox-mold
Are you looking for a reliable supplier of silicone rubber molds with guaranteed quality? Welcome to Fox Mold. Our company offers a wide variety of services that pertain to prototyping manufacturing such as injection molding and CNC machining, Whether you require highly elaborate prototypes or accurate first and second tool parts, Fox Mold offers optimum and economic solutions for your requirements. Call us today to get a quote within the shortest time possible!
FAQ’s
Q1. How do LSR and traditional silicone molding differ?
LSR injection molding works with a liquid silicone by melting it. This it can produce intricate designs and meet tight tolerances. However, the conventional silicone molding solution utilizes solid silicone and normally tends to incur more expense and complexity in the process. Additionally, they are not as accurate as LSR.
Q2. What are the properties of LSR?
Liquid silicone rubber has good biocompatibility, and flexibility and can withstand high temperatures up to 250 °C. This allows it to flow easily into molds to create designs with high complexity without affecting the material strength.
Q3. What is the curing process of LSR in LSR injection molding?
Curing is carried out by using heat treatment to the liquid silicone in the mold after injection to activate the platinum. This leads to the formation of additional links between polymer chains.
Q4. What difficulties can be met at the time of liquid silicone Liquid Silicone Rubber Injection Molding?
The difficulties associated with using LSR material are high initial costs and longer cycle times as compared to those of thermoplastics. However, a proper parting line is essential to avoid leakage in this area since it results in a flash, which may compromise the product quality.
This guide presents information about the LSR injection molding process. In addition, it provides the process steps involved, the applications, primary benefits, and design considerations. Let’s explore further!
What Is LSR Injection Molding?
Liquid silicone rubber (LSR), is a high-purity cured silicone rubber. It’s a chemically stable thermosetting polymer that has desirable features such as biocompatibility, chemical and water resistance, high compression rates, fire, and heat resistance up to 250 °C.
The molding process used to injection mold LSR is referred to as liquid silicone rubber molding. LSR molding is comparatively distinct from regular injection molding equipment. It comprises a metering pump that pumps the two liquids; a catalyst and the base silicone separately. Further, it mixes them before feeding into the pre-defined mold.
In operation, the mold cavity is subjected to heating to cause silicon vulcanization. Moreover, LSR is a thermoset material and to solidify the material to bring it into the network of polymer chains, heat is crucial. LSR is produced through the injection molding process, in which a low-viscosity two-component compound is mixed and heat-cured in a mold with the help of a platinum catalyst to form a functional LSR part.
How Does Liquid Silicone Rubber Injection Molding Work?
The process steps of Liquid Silicone Rubber Injection Molding are given below;
▶Step 01: Tool Creation:
The mold is developed and produced through kinds of machining process to meet the requirements of high-temperature usage for the LSR process.
▶Step 02: Material Preparation
Two components are prepared: the base silicone substance and the platinum catalyzer. These materials are stored in different tanks but for measurement purposes, they are connected to a meterage system.
▶Step 03: Mixing Components
The base silicone and catalyst are pumped in a precise 1:1 through a static or dynamic mixer. This ensures a well-mixed and homogeneous compound.
▶Step 04: Injection into Mold
The mixed LSR is heated and high-pressure injected into the mold cavity of the detailed member features.
▶Step 05: Curing Process
The mold is heated to cause the cross-linking of the silicone. So, helps form a rigid part with the desired characteristics.
▶Step 06: Cooling and Demolding
Once set the molds are cooled and then they are taken apart very slowly to free the molded parts. This may be done manually or with the help of automated systems.
▶Step 07: Post-Molding Operations
Subsequent operations may be required after demolding is accomplished. These are slitting, printing, marking, assembling, and post-curing to give the final shape to the products.
Comparing LSR Injection To Convention Injection Molding
Here’s a comparison table including technical details related to comparing LSR Injection Molding to conventional molding techniques:
Industrial Applications of LSR Injection Molding
Liquid silicone rubber (LSR) injection molding is a highly adaptable process used across various manufacturing industries:
●Medical and Healthcare
Biocompatibility is one of LSR’s most outstanding properties to makes it compatible with medicine. It is soft and flexible and enables the skin to be in contact with for a long without any danger. Some common uses include seals gaskets and surgical instruments. Moreover, several applications are made of injection molded parts such as drug delivery systems and catheters, respiratory masks, and medical equipment enclosures.
●Automotive Industry
LSR’s thermal stability is advantageous in the automotive industry. It is heat resistant around the engine and other parts. LSR molding products are used in seals, connectors, and electronic covering. Moreover, these are exploited in windshield wiper blades because it does not scratch the plastic used in the wiper blades. These blades last longer than other rubber blades.
●Electronics
Due to its electrical insulation characteristics, electronic sectors heavily use LSR. Some common products included; keypads, buttons, watertight gaskets, and many more. It also supplies seals and connectors for different devices.
●Consumer Products
LSR molding is highly used in manufacturing kitchenware and toys. Pacifiers, infant bottles, and wristwatches for example are some of the products usually made by silicone injection molding. These attributes further contribute to consumer good appeal because of the flexibility and easy-to-clean design.
Overall, LSR molding has several advantages. Even though the process may involve the use of special equipment. Because of its outstanding compression set, it is invaluable to various sectors. Such products include silicone medical implants and drug-delivery devices. Other include hearing aid tips, shower heads, and protective covers. LSR is also proficient in developing thermal stable parts for automotive, and aircraft use.
Advantages & Disadvantages of LSR Injection Molding
Here are the primary benefits and drawbacks of liquid silicone rubber injection molding;
● High Biocompatibility: LSR is nonirritant and can be used where skin contact may be prolonged. Therefore, it is well suitable for the medical field.
● Good Thermal Stability: LSR has high heat resistance and can operate in temperature conditions that reach 250 °C.
● Precision Tolerances: Silicone injection molding delivers dimensional control within ±0.01 mm to ±0.05 mm for complex geometries.
● Durability and Longevity: LSR compound has high chemical stability and keeps its properties for a long time. Moreover, these products cannot be degraded by UV light.
● Multiple Design Options: The molding process also permits intricate shapes and different surface coatings; thus, increasing the possibilities of design.
As you know, no process or material is perfect, and LSR injection molding has its flaws.
● Higher Initial Costs: LSR molding setup needs certain equipment which raises the initial process cost than conventional molding processes.
● Longer Cycle Times: LSR molding cycles are typically longer than in conventional thermoplastics, 30-60 seconds as opposed to 15-30 seconds.
● Limited Material Choices: However, it has different properties than other thermoplastics. So, fewer materials can be combined with LSR. In addition, the complexity of the processing requirements of these biobanks becomes apparent.
● Problems Related To High Production Quantities: LSR injection molding requires higher setup costs and longer cycles making the technique less efficient when it comes to large volumes of production.
Materials Compatible For LSR Injection Molding
Here’s a table listing materials compatible with LSR molding along with their applications:
Material
Applications
Liquid Silicone Rubber (LSR)
Medical devices (catheters, seals, surgical instruments)
Platinum-Cured Silicone
Food-grade kitchenware (molds, baking mats)
Silicone Elastomers
Automotive parts (gaskets, seals, wiper blades)
High-Temperature Silicone
Electronics (keypads, switches, connectors)
Colored Silicones
Consumer products (toys, wristbands, baby products)
Flame-Retardant Silicone
Industrial applications (grommets, strain relief devices)
UV-Stabilized Silicone
Outdoor products (shower heads, garden equipment)
Conductive Silicone
Electronic components (sensors, conductive pads)
Design Considerations for LSR Injection Molding
Several design and manufacturing factors are critical to successful LSR injection molding. Below are critical aspects to keep in mind:
✔Part Design Guidelines
It’s crucial to design the components to be molded in LSR molding differently from thermoplastic molding techniques. Interestingly, silicone parts are recognized for their simpler design requirements.
● Electability: The mentioned flexibility of silicone ensures easy removal from the molds. The ejection pin layout is not a fundamental design consideration. As parts can typically be pulled out of a mold manually. It has the benefit of permitting more free draft angles.
● Wall Thickness Variation: LSR’s ability to be shear thinning means that fewer parts need to be made with uniform wall thicknesses because the material can flow. As a result, silicone parts can be designed to be thicker than thermoplastic parts.
● Protruding Undercuts: LSR can deal with protruding undercut features because this material is rather flexible and the parts with such features can be easily extracted without the usage of additional side-action mechanisms.
● Sealing Requirements: As LSR has a low viscosity, it can seep out through the parting line if not well closed. Tooling seals must fit, and be enclosed well to minimize material loss.
✔General Design Rules
● Parting Lines: Parting phrases should be brief as a way of reducing the flash impact.
● Draft Angles: For shallow parts, no draft may be required; otherwise try for one degree of draft per 2.5 cm.
● Gate Placement: Mount position gates at the bottom of the least obvious places to retain design.
✔Metering and Mixing Process
Unlike thermoplastic or plastic injection molding, LSR injection employs two components: An organ polysiloxane base silicone and a platinum catalyst. These materials are delivered in a fixed proportion through a metering unit and combined with a static or dynamic mixer.
✔Other Manufacturing Factors
● Bonding Support: Make sure the process and mold design allow for good adhesion between the substrate and LSR.
● Dimension Variability: The thickness of the winding can vary due to the curing and material shrinkage therefore shade allowances should be made based on these conditions. It is advised to consult the mold designers to get the correct dimensions.
● Draft Angles and Undercuts: It’s recommended to design the parts with the correct draft angles and minimize the undercuts to ease the ejection process.
● Surface Texture Selection: Select the right textures for the silicone parts that will meet the functional aspects, as well as the aesthetic aspects.
● Optimal Mold Design: The mold design features of gate locations, vents, and cooling system should be well optimized to increase the part quality and decrease the cycle time.
Conclusion
Liquid silicone rubber injection molding is versatile and economical. It provides more efficient manufacturing benefits than the other molding techniques. The process is optimal for complex designs with high dimensional accuracy throughout. Moreover, It’s adaptable and has become indispensable for different fields and companies. Automotive, Aerospace, and electronic sectors are the primary consumers of LSR injection molded products.
Affordable Custom LSR Molding Services at Fox-mold
Are you looking for a reliable supplier of silicone rubber molds with guaranteed quality? Welcome to Fox Mold. Our company offers a wide variety of services that pertain to prototyping manufacturing such as injection molding and CNC machining, Whether you require highly elaborate prototypes or accurate first and second tool parts, Fox Mold offers optimum and economic solutions for your requirements. Call us today to get a quote within the shortest time possible!
FAQ’s
Q1. How do LSR and traditional silicone molding differ?
LSR injection molding works with a liquid silicone by melting it. This it can produce intricate designs and meet tight tolerances. However, the conventional silicone molding solution utilizes solid silicone and normally tends to incur more expense and complexity in the process. Additionally, they are not as accurate as LSR.
Q2. What are the properties of LSR?
Liquid silicone rubber has good biocompatibility, and flexibility and can withstand high temperatures up to 250 °C. This allows it to flow easily into molds to create designs with high complexity without affecting the material strength.
Q3. What is the curing process of LSR in LSR injection molding?
Curing is carried out by using heat treatment to the liquid silicone in the mold after injection to activate the platinum. This leads to the formation of additional links between polymer chains.
Q4. What difficulties can be met at the time of liquid silicone Liquid Silicone Rubber Injection Molding?
The difficulties associated with using LSR material are high initial costs and longer cycle times as compared to those of thermoplastics. However, a proper parting line is essential to avoid leakage in this area since it results in a flash, which may compromise the product quality.
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