| Molding Type | Best Use Cases | Typical Materials | Typical Tolerance | Key Advantages | Considerations |
| Rubber Injection Molding | High-volume production, tight tolerances, complex geometries | TPEs. TPVs, TPRs, elastomers | ±0.05–0.20 mm (±0.002–0.01 in) | Excellent dimensional precision, low material waste, highly consistent part quality | Higher tooling costs; limited to elastomers with good flow characteristics |
| Compression Molding | Medium production runs, large or bulky parts (e.g., gaskets, seals, O-rings) | NR, EPDM, CR (neoprene), silicone rubber, NBR, IIR | ±0.20–0.50 mm (±0.008–0.020 in) | Lower tooling cost, wide range of compatible rubber materials | Longer cycle times; limited ability to form fine or intricate features |
| (LSR) Injection Molding | Medical, food-grade, harsh environments, high-purity flexible components | Platinum-cured liquid silicone rubber | ±0.05–0.1 mm (±0.002–0.005 in) | Extremely high precision, fast cycle times, biocompatible and heat-resistant | High initial equipment investment; restricted to silicone rubber materials |
| Vacuum Casting | Prototyping, bridge production, pre-production validation | Silicone elastomers, PU elastomer resins, rubber-like casting materials | ±0.10–0.30 mm (±0.004–0.012 in) | Quick turnaround, low upfront cost for small batches, excellent surface detail | Short mold life, limited material options; not suitable for mass production |
- Superior precision: Ideal for intricate designs requiring exact dimensions.
- Efficient production: Suitable for high-volume manufacturing, offering consistency.
- Minimal waste: Produces less scrap material, enhancing cost-effectiveness.
- Limited material compatibility: Best suited for silicone rubber molding and similar materials.
- Higher initial costs: Investment in specialized machinery can be substantial.
- Versatility: Adaptable for various materials, including black rubber molding.
- Cost-effective: Lower tooling costs, making it suitable for custom rubber molding projects.
- Simplified process: Easier to manage and maintain, especially for flexible rubber molding.
- Limited complexity: Not ideal for extremely detailed or thin-walled designs.
- Longer cycle times: May not be suitable for large-scale production demands.
- High-quality surface finish.
- Excellent detail replication.
- Fast turnaround time.
- Lower cost for small batches.
- Wide range of materials (rigid, flexible, transparent, etc.).
- Ideal for functional prototypes and pre-production testing.
- Limited Material Selection
- Shorter Lifespan of Molds.
- Dimensional Accuracy Limits.
- Slower Production Speed vs. Other Rubber Molding Processes.
- Size Restrictions.
- Not Cost-Effective for Large Quantities.
- High Precision & Consistency: Good to manufacture complex shapes parts in tight tolerances.
- Fast Cycle Times: Automated mixing, injection, and curing make it faster than traditional compression molding.
- Material Properties: Produces parts with outstanding flexibility, heat resistance, and biocompatibility.
- High Initial Cost: Tooling and LIM machines are expensive, making it less cost-effective for low-volume runs.
- Limited Material Options: Only works with liquid silicone rubbers (not suitable for solid rubbers or thermoplastics).
- Demolding Challenges: Soft, elastic parts can be tricky to remove without specialized tooling or automation.
| Category | Typical Rubber Parts | Common Rubber Materials | |
| Seals & Gaskets | O-rings, flat gaskets, flange seals, lip seals, X-rings | NBR, EPDM, FKM, Silicone, Neoprene | Compression, Injection |
| Automotive | Bushings, engine mounts, CV boots, weatherstrips | NR, EPDM, NBR, CR | Injection, Compression |
| Industrial Machinery | Diaphragms, bellows, rollers, couplings | NBR, EPDM, PU, NR | Compression, Transfer |
| Vibration & NVH | Anti-vibration mounts, isolators, dampers | NR, EPDM, Silicone | Compression, Bonded molding |
| Rubber-to-Metal Bonded | Engine mounts, shear mounts, sleeves | NR, NBR, EPDM | Compression, Transfer |
| Fluid Control | Valve seats, duckbill valves, pump impellers | EPDM, Silicone, FKM | Injection, Compression |
| Electrical & Electronics | Grommets, connector seals, keypads | Silicone, EPDM | Injection, LSR molding |
| Medical & Healthcare | Syringe plungers, stoppers, mask seals | Medical Silicone, EPDM | Injection, Compression |
| Food & Beverage | Sanitary gaskets, pump diaphragms | FDA Silicone, EPDM | Compression, Injection |
| Aerospace & Defense | Fuel seals, fire-resistant gaskets | FKM, Silicone, Fluorosilicone | Injection, Transfer |
| Oil & Gas | Packings, chevron seals, BOP seals | FKM, HNBR, NBR | Compression, Transfer |
| Construction | Expansion joint seals, glazing rubber | EPDM, Neoprene | Extrusion + molding |
| HVAC Systems | Duct seals, vibration pads | EPDM, NR | Compression |
| Marine & Offshore | Hatch seals, fenders, dock bumpers | EPDM, NR | Compression |
| Agriculture | Sprayer diaphragms, tractor bushings | NBR, NR | Compression |
| Mining & Heavy Duty | Chute liners, wear pads, skirting | NR, Abrasion-resistant rubber | Compression |
| Packaging & Automation | Suction cups, grippers | Silicone, PU | Injection |
| Consumer Products | Grips, feet, protective bumpers | TPE, Silicone, NR | Injection |
| Optical & Lighting | Lens seals, light-blocking gaskets | Silicone, EPDM | Injection |
| Smart Devices | Button membranes, port seals | Silicone, LSR | Injection (LSR) |
| Laboratory Equipment | Vacuum seals, autoclave gaskets | Silicone, FKM | Compression |
| Fire & Safety | Breathing mask parts, fire hose seals | Silicone, EPDM | Compression |
| Railway & Transit | Rail pads, door seals | NR, EPDM | Compression |
| Furniture & Architecture | Edge trims, glazing gaskets | EPDM, TPE | Compression |
| Environmental & Water | Filter membranes, pipe seals | EPDM, NBR | Compression |
| Specialty & Extreme Use | Cryogenic seals, radiation-resistant parts | Silicone, FKM, specialty elastomers | Compression |
| Disposable Rubber Parts | Vial stoppers, single-use valves | Silicone, EPDM | Injection |
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