What Is Compression Molding?
Compression molding is a highly advanced manufacturing process that can be used to create a wide variety of finished products. Developed in 1909 to manufacture parts to replace metal machinery components, compression molding is a method of creating finished products from a heated and molded material such as synthetic or natural rubber. Compression molding was originally developed for, and is most generally utilized for, creating larger parts that are slightly curved or flat. However, compression molding is also suitable for the manufacture of smaller, more intricate parts. Automotive parts are some of the major products created through the compression molding process, with sheet molding or bulk molding compounds being the base product
The compression molding process requires that the rubber compound be placed in the mold just prior to heat being applied. The rubber compound (which may be preheated prior to placement in the mold to reduce flash and shorten the molding cycle) is placed in the heated mold cavity which is then closed with a hydraulic ram to force-shape the material to fit the mold. Platens hold the two sides of the mold in place while the mold is heated. Pressure is then applied, causing the compound to make contact with all areas of the mold. Normally, pressure requirements are at least 1,500 PSI, and the compression molding time is usually around four minutes. Temperatures must reach or exceed 350 degrees Fahrenheit in order to soften the material, form it to the mold, and cause the two sides of the molded material to fuse together. Heat, along with pressure, will result in the rubber compound forming to the molded shape. Quality compression molding results from the even distribution of rubber compound over the surface of the mold itself. Post-production, the cooling temperature of the rubber compound is essential in creating a quality finished piece. The resulting part or stand-alone product is a dense, heavy item that often has an indefinite shelf-life.
One of the foremost advantages of compression molding is that relatively intricate component parts or stand-alone products can be produced in various sizes. The inexpensive overhead involved with compression molding, and the comparatively little waste material that results from the manufacturing process, also makes compression molding a preferred method of manufacturing. Compared with other types of manufacturing processes, the cost of parts produced through compression molding is relatively low.
Because of its advantages over other manufacturing processes, compression molding is the preferred manufacturing method for a wide variety of parts and components used in many different industries. Compression molding is a process ideally suited for producing large, simple-shaped items which exceed the sizes that can be manufactured through other manufacturing processes such as extrusion. While compression molding has many advantages, it is not a process that can be used with all rubber compounds or in the manufacturing of all rubber products. For example, since it can be difficult to control the flash produced in the compression molding process, compression molding is not a suitable method for manufacturing certain types of precision parts.
Products created from compression molding include a wide range of items. Automotive parts, as well as a wide range of components used in electrical equipment, plumbing, and hydraulic applications can all be produced through the compression molding process. Many of the items used in everyday kitchens and restaurants, including the handles for cooking pots, cafeteria trays, kitchen utensils and dinnerware, can also be manufactured through compression molding. Compression molding has proven to be an essential part of the modern manufacturing environment.
Our custom rubber molding includes any shape of rubber parts such as o-rings, gaskets, washers, oil seals, square rings, quad rings, D- rings, X-rings, u-cups, grommets, diaphragms, packings, rubber boots, rubber balls, rubber bonded to metal and productions per your prints and designs.
August 26, 2010 | Posted by Henry Wolf
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