Rubber to metal molding process used to create bumpers for trains.
The Rubber to Metal Bonding Process
Utilizing injection molding and transfer molding to encapsulate and bond rubber to metal is the most effective way to adhere rubber to metal or plastic parts. Furthermore, the rubber to metal molding process provides a superior mechanical bond of rubber to metal parts, inserts or plastic parts.
Two Step Process
The process requires a two-step preparation of the metal or plastic part prior to molding the rubber. First, we degrease and clean off any contaminants, similar to preparation for industrial coatings or painting. Once we finish cleaning, we spray a special, heat-activated adhesive onto the metal parts.
Once the part is ready for rubber overmolding, the metal parts are inserted into the mold cavity. If molding a specific area, the metal part is held in place by special magnets. If the part is to be completely encapsulated with rubber, the part is held in place with chaplet pins. The mold is then closed and the rubber molding process begins. As the elevated molding temperature cures the rubber, it also activates the adhesive forming a mechanical bonding of rubber to metal or bonding rubber to plastic. To learn more about the our bonding processes, click on the following links: rubber injection molding process or transfer molding process.
Encapsulating with Rubber to Metal Bonding
When a metal or plastic part requires complete encapsulation with rubber, we use rubber insert molding, a variation of rubber to metal bonding. For complete encapsulation, the plastic or metal part is suspended inside the bold cavity, so we can more accurately bond the rubber to the part. Rubber can also be molded to a specific area of metal parts. Mechanically adhering rubber to metal can enhance the stability of metal parts with the flexible characteristics of rubber. Metal parts with molded rubber can also improve part properties such as creating environmental seals, meeting NEMA standards, electrical conductivity, noise and vibration isolation, wear and impact resistance, chemical and corrosion resistance and more.
Materials that can be insert molded, overmolded or bonded of a specific area include: steel, brass, aluminum, alloys, exotics, engineered resins and plastics.
Additionally, rubber bonded to metal ranges in parts and in size from small inserts to very large components. Overmolded rubber metal parts are applicable across a broad range of industries and applications.
Types of Rubber We Mold
Qualiform molds both natural rubber and synthetic rubber which include:
- Colored Compounds
- Natural Rubber
- Fiber Molding
Our technical staff is available to answer any questions. Call (330) 336-6777, or submit a question through our Contact Form or Send Us a PDF.
Rubber Molding FAQ’s
Please provide us with a sample or print of your part to be reviewed. To assist us in the tooling design, include the estimate of your annual usage requirements. Also include the type of material, unless it is unknown or unspecified. In that situation, please describe the environment in which the tooling will be utilized.
If you desire, Qualiform will be there to assist you in your design process from the initial phase to the final step of approving your part.
Qualiform is capable of offering expert recommendations for polymers and an indication of your durometer requirements.
The average lead times vary by type of tooling. For prototype tools, the average lead-time is 2-4 weeks. For compression or transfer molding, the average lead-time is 6-8 weeks. For rubber injection molding tooling, the average lead-time is 8-10 weeks. However, if you need an expedited tooling lead time, we are able to work with our tooling shop to meet your time requirements.
We purchase all of our tooling within the United States. This allows us to respond quickly to customer changes and work with faster lead-times.
A majority of our parts can be shipped out within 3-4 weeks from the receipt of the order, depending on the number of products.
Tooling will fit into our presses in most cases. However, sometimes minor tooling modifications may be necessary.
After we receive payment for the product, the tooling is the customer’s property. Tooling is custom to each customer’s specific design requests.
We work with a variety of supply chains to source required metal stamping or inserts.
We work closely with our rubber supplies to obtain color matches that fit our customers’ specific requests.
Qualiform Rubber Molding Company
Within the rubber molding industry, Qualiform is one of the top American rubber molding companies. We create each customer’s products using special compounds and unique designs, so we can meet their exact specifications. We also tackle specific molding challenge using problem-solving abilities we’ve acquired through comprehensive experience in rubber molding and rubber-to-metal molding or bonding.
Qualiform Rubber Molding is certified through ISO 9001:2015. As a result, we can meet our customers’ specific needs through attentive customer service and top quality customer rubber-molded products. If you’re in need of any help with project development, contact us. In addition to rubber to metal bonding, we offer a variety of expert molding services including injection molding, compression molding, transfer molding, and rubber-to-metal bonding.
In addition to superior product development, Qualiform’s highly trained employees are here to aid you throughout your complete design and development process. We’ll work hard to make sure that we meet your needs and specifications for every project. Furthermore, we will ensure that the materials and product quality are to your satisfaction at each individual step of your product’s development. Contact a member of our technical staff at (330) 336-6777 or CLICK HERE to send us a drawing.
Qualiform Quality Assurance Program
Qualiform Rubber Molding is an ISO 9001:2015. We commit to enacting the most effective quality assurance program. This selected program oversees, evaluates, and documents every part of our molding process. Thus, we are able to follow customer requirements and ensure customer satisfaction with all products and services that we offer.
To maintain competitive pricing options, Qualiform examines all aspects of part production. Each product is evaluated to create the best-customized solutions and prices via R&D, design, manufacturing, or engineering, so we can ensure each customer receives exactly what they need.
Expert Work Force
Here at Qualiform Rubber Molding, we have over 30 years of expertise in rubber molding under our belt, so we can tackle virtually any rubber manufacturing challenge. We equip our leadership team to provide unparalleled service. Each of our individual employees is a highly valuable asset to the company. We invest our employees their skills sets and expertise so that they, in turn, act as leaders to produce top quality products.
Our excellent customer service provides dependable and considerate communication with customers. We make sure to follow-up with customers, explaining exact details of each step of the manufacturing process for a specific product.
From Start to Finish
From initial design to final inspection, Qualiform will create your product design with excellent customer service. We manufacture quality rubber compression molding, custom transfer molding, rubber to metal molding or bonding, and custom injection molding. Our well-rounded manufacturing abilities enable us to complete jobs that other manufacturers would fail at.
Since 1976, Qualiform has been building the experience and knowledge to master your custom rubber molding projects. We’ve built our respected reputation on dedication to customer service and superior product quality. We provide numerous services such as rubber compression molding, rubber injection molding, and rubber transfer molding, rubber to metal molding or bodning, and color compounds. Our wide range of capabilities puts us in the position to provide any custom molded rubber product that you may need.
Qualiform services include custom rubber molding, custom rubber transfer molding, rubber parts manufacturer, custom rubber injection molding, custom rubber compression molding, rubber to metal molding and bonding, and rubber products manufacturer.
Our technical staff is available to answer any questions call (330) 336-6777, or submit a question through our Contact Form or Send Us a PDF.