Manufacturing Tips for The Average Joe
When it comes to rubber products manufacturing, there are many manufacturing processes that are applied. Every procedure has certain benefits, which makes it the perfect choice for the manufacturing of certain kinds of product. Making yourself aware of the different manufacturing processes can help you to have better understanding of tradeoffs and cost implications.
Some of the frequently used rubber products manufacturing are extrusion, molding, latex dipping as well as calendaring.
Extrusion – this starts with unvulcanized compound that’s fed into extruder. The moment that it’s inside the extruder, it will be carried forward to the dye, which is basically a specialized manufacturing tool used to mold the rubber. As soon as the compound has reached the dye, the pressure forces it through the extruder’s opening. The extruded product then has to be vulcanized before it can be considered usable.
Latex dipping – for this, it takes place when a thin walled mold is immersed to the latex compounds and slowly withdrawn. Re-dipping the product in the latex compound will increase the thickness of the dipped product. When the dipping process has occurred, the product is now finished in vulcanization. Depending on finished dipped product, it may require post treatments.
Molding – this composed of three primary manufacturing processes including transfer molding, injection molding and compression molding. For the latter, it’s the least expensive and at the same time, the oldest technique. With this procedure, rubber compound is formed into blank or chunk of rubber. For it to be shaped, the blank is positioned to the mold cavity. There is a slow heating time which leads to a long curing time. Heating might vary from 90 seconds for thin walls and can last for several hours for thicker walls.
In order to limit the drawbacks of compression molding, transfer molding is used. The procedure begins with a blank being loaded in chamber. Then after, this is distributed into several cavities. From the early phase of it, preheating will begin in rubber which is going to force the rubber to flow through channels. This reduces curing time and lets the rubber to flow easier and to fill in mold cavities with higher efficiency.
For rubber products manufacturing, injection molding is the most common procedure used. With this kind of procedure, the press units and the injection unit serve as separate entities which come with individual controls too. With this type of molding, there is no blanks handling and processes may be automated and the difficult cavities as well as flow channels can be easily filled.
Calendering – this one functions by forcing softened materials to center of counter rotating rollers. The rollers will be compacting the materials while the product’s overall thickness is set by the gap distance between the cylinders.