Rubber Injection Molding

Rubber Injection Molding2018-12-02T22:50:03+00:00

Rubber Injection Molding

The Custom Rubber Injection Molding Experts

With over thirty years of experience with rubber injection molding, Qualiform offers competitive pricing combined with unparalleled product quality and service.  Qualiform Rubber Molding is a leading provider of rubber injection molding to OEMs across the US.  OEMs rely on our expertise in material properties and rubber compound selection, design consultation and complex part molding.

Qualiform is certified to ISO 9001:2015 and experienced in meeting the strictest quality standards.

Rubber Injection Molding

Rubber injection molding is used to develop both solid rubber parts and rubber-to-metal bonded products.  Natural and synthetic rubber compounds can provide a wide variety of properties that solve problems from seals or gaskets, noise and vibration isolation, abrasion and impact resistance and chemical/corrosion resistance.  Rubber injection molding is an ideally suited for mid-to-high-volume production and where tight tolerances, part consistency or over-molding are required.  In addition, rubber injection molding works well with rubber compounds that have faster cure times.  This is a process that can be fully automated.

The Rubber Injection Molding Process

Rubber injection molding was first used in the mid-1960s and was based on the plastic injection molding process.  The key difference between plastic and rubber injection molding is that in rubber requires significantly higher pressure to cure the rubber thus leading to longer cure times.

The process starts with the tooling, a rubber injection mold typically with multiple cavities.  The mold consists of a nozzle plate, runner plate, cavity plate, and a base plate with a post-molding ejector system.  The rubber compounds and additives are mixed to create rubber stock.  The stock is formed into continuous strips of uncured rubber stock approximately 1.25″ wide & .375″.

The continuous strip is automatically fed from a hopper into the injection molding machine into a heated barrel, conveyance channel, which softens, plasticizes the rubber.  The stock is then pushed by a large auger, screw-type plunger through the injection nozzle. After flowing into the nozzle plate, the rubber is routed through the runner plate, through the gates, and then into the mold cavities.

When the cavities have been filled the heated mold is kept closed under pressure. The temperature and pressure activate the cure of the rubber compound, vulcanizing it.  Once the rubber reaches and required level of cure, it is allowed to cool and reach a solid state within the mold. The molds open and parts are removed or ejected and ready for the next cycle.

In cases where rubber injection molding is used to encapsulate metal components with rubber or bond rubber to metal, the components are loaded, either by hand or using a loading fixture, into the heated mold cavities. The mold is then closed and the injection molding cycle can begin. After curing is completed, the mold is opened and parts are removed. The cured rubber in the runner is removed, cured rubber in the injection nozzle is purged, and the mold cavities are cleaned in preparation for the next molding cycle.

Rubber Injection Molding Advantages

  • A mid-to-high volume, efficient process
  • Full automation is available
  • Provides high-tolerance, precision rubber molded products
  • The best rubber process for consistency and repeatability
  • Allows for molding of complex geometry
  • Ideal for rubber to metal bonding,  insert molding and over-molding
  • Color molded rubber
  • Lower unit cost
  • Eliminates preforms and preform labor cost
  • Flashless molding / flashless tooling / eliminating secondary trimming
  • Rapid cavity filling
  • Reduced cycle time
  • Minimal material waste

Rubber Injection Molding Disadvantages

  • Higher start-up/shutdown costs
  • Suited for high volume applications
  • Not all elastomers are suitable due to fast cure times

Typical Parts Produced with Rubber Injection Molding

  • Rubber boots
  • Rubber gaskets
  • Rubber seals
  • Rubber grommets
  • Colored rubber products
  • Rubber bumpers
  • Rubber grips
  • Rubber diaphragms
  • Rubber bellows
  • Rubber shock absorbers
  • Rubber to metal bonding products
  • Complex rubber products
  • Vibration control parts / vibration isolation parts
  • Chemical or corrosion resistant parts
  • Abrasion-resistant parts
  • Custom rubber parts

Materials We Process

  • Butyl
  • SBR
  • Natural Rubber
  • Silicone
  • Colored Compounds
  • EPDM
  • Nitrile
  • Viton©
  • Neoprene

Rubber Molding Capabilities

Different molding processes have different strengths.  That’s why Qualiform offers quality custom rubber compression molding, custom transfer molding, custom rubber injection molding, and rubber to metal bonding .  Our experts help you match the best process to your project.

Our technical staff is available to answer any questions call (330) 336-6777, or submit a question / inquiry through our Contact Form or Send Us a PDF.

About

For over 30 years, Qualiform Rubber Molding has provided full-service manufacturing and quality rubber products to their customers.  With reputable and dependable rubber products, our manufacturing capabilities meet the needs necessitated by the transportation, medical, electrical, plumbing, industrial, appliance, and aerospace industries.

Why Qualiform for your Rubber Injection Molding?

With unparalleled experience, Qualiform is the top U.S. rubber molder for custom rubber products.  At Qualiform, we know that quality custom rubber products often require special compounds and present unique design and molding challenges.  Our team of problem-solving, experts are well-equipped to handle all aspects of rubber molding and rubber to metal bonding with the utmost regards to their customers.

As the leading supplier of rubber molding services, compression molding, transfer molding, rubber to metal bonding and rubber injection molding, we at Qualiform understand the importance of a fast turnaround.  We are committed to running a 3-shift, 24-hour production facility for the quickest possible turnaround.  

As a certified ISO 9001 company, we are dedicated to producing high-quality custom rubber molded products while taking the necessary steps to understand your project needs and ensure that they meet your full satisfaction.  Qualiform is committed to implementing an effective quality assurance program that oversees, evaluates and documents every aspect of our process, assuring top-notch quality with every product and service that we provide to our customers.

Qualiform is committed to our customers, our environment and our country.  The competitive pricing that Qualiform offers our customers is a result of evaluating every aspect required to produce the part.  Through research and development, our team at Qualiform analyzes the entire project scope to provide our customers with the best solution at the best price.

Green initiatives are taken by using repurposed rubber as often as we can.  In turn, we are able to reduce costs and limit the amount of waste going into landfills.

As an American-Owned company that works solely with American-Made products, Qualiform sources all of our tooling from within the United States.  This allows faster-lead times and faster responses to customer design changes.

Our Services

Thanks to our talented team, Qualiform is deemed a full-service manufacturer.  We manufacture various types of products, offer numerous rubber processes and process additional materials as well.  For a full list of our services, see below.

Frequently Asked Questions

What’s the process to get a quote?

The process is simple. All you need to do is provide us with a print or a sample of the desired part for review.  To assist with tooling design, provide your estimated annual usage requirements along with the desired material.  If the material is unspecified or unknown, just describe the environment in which it will be used and our team will come up with the best possible solution.  It’s as simple as that, the rest is on us.

Can Qualiform assist with the design of my custom rubber injection molding part?

Absolutely! Qualiform Rubber Molding can assist in the initial design phase all the way through to final approval.

What if I don’t know which polymer or durometer is best suited for my application?

Call on Qualiform’s 32+ years of experience to assist you in determining the proper polymer for your application as well as your durometer requirements.

What is the lead-time when I place an order that requires a tool?

All tooling that Qualiform uses is manufactured in the U.S., allowing for faster lead-times.  The average lead-time for prototype tools is 2-4 weeks.  For production compression or transfer tooling, lead-time is 6-8 weeks.  Average production rubber injection molding tooling is 8-10 weeks.  At Qualiform we understand that there may be instances that will entail improved tooling lead-time and we are committed to working with our tooling shop to meet customer requirements.

Can Qualiform use existing tooling?

In most cases, tooling will fit into Qualiform’s presses.  Occasionally, a minor tooling modification may be necessary.

Once I pay for the rubber molding tooling, who owns the tooling?

Tooling is part of the customization we provide our customers with.  It is part of our customer’s design and therefore their property once payment is received.

What is Qualiform’s part lead-time?

From the receipt of order and depending on the order quantity, most parts can be shipped per order requirements in 3-4 weeks.

For rubber-to-metal bonding applications, can Qualiform source my metal components?

We’ve got connections! Qualiform works with several supply chains to source the required metal stamping or insert.

Can Qualiform match my custom color requirements?

We mean it when we say full-service manufacturing.  Qualiform works with our rubber suppliers to provide exact color matches for your requests.

Additional Questions

Our technical staff is available to answer any questions you may have.  Qualiform customer service support provides reliable, courteous and responsible communication that includes a detail-oriented follow-up with every customer.

Call us at (330) 336-6777 or submit an inquiry through our contact form.

Custom Injection Molding

Our technical staff is ready to assist you with all your custom rubber injection molding needs.

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An example of a flexible strain relief protector.

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