Liquid Silicone Rubber Injection Molding Machine Manufacturing Service

Manufacturing Insight: Liquid Silicone Rubber Injection Molding Machine

Precision Liquid Silicone Rubber Injection Molding Solutions from Honyo Prototype

Liquid silicone rubber (LSR) injection molding delivers exceptional performance for mission-critical components in medical, automotive, and consumer electronics applications, where biocompatibility, thermal stability, and long-term durability are non-negotiable. However, traditional LSR production faces significant hurdles: complex material behavior, extended tooling lead times, and high non-recurring engineering costs that delay time-to-market and inflate prototyping expenses.

Honyo Prototype directly addresses these challenges through an integrated Rapid Tooling and Injection Molding service platform engineered for speed and precision. Our proprietary rapid tooling process leverages advanced CNC machining and EDM techniques to produce production-ready LSR molds in as little as 10–15 business days—accelerating validation cycles without compromising on critical features like micro-shutoffs or venting precision. Coupled with our dedicated LSR molding cells featuring calibrated 50–350-ton hydraulic presses, closed-loop process control, and in-house material compounding, we ensure seamless transition from prototype to volume production under ISO 9001-controlled conditions. This vertical integration eliminates supply chain handoffs, reduces scrap rates by up to 30%, and guarantees consistent part quality across all phases.

Accelerate your development timeline immediately with Honyo’s Online Instant Quote system. Upload your 3D CAD file and receive a detailed, geometry-validated quotation for both rapid tooling and injection molding within hours—not days—enabling faster decision-making and project initiation.

Service Component	Key Advantage	Typical Lead Time Reduction
Rapid LSR Tooling	Production-intent molds for validation & low-volume runs	50–70% vs. conventional
Precision LSR Molding	Full process validation with DOE and SPC documentation	N/A (enables first-pass success)
Online Instant Quote	Real-time cost feedback for DFM optimization	Quotation in <4 business hours

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Technical Capabilities

Liquid Silicone Rubber (LSR) injection molding machines are engineered for high-precision, repeatable production of silicone components using thermoset processes. When the focus is on rapid prototyping with T1 sample delivery within 7 days, the integration of aluminum or steel molds becomes critical for balancing speed, durability, and detail accuracy. These machines are typically paired with either aluminum molds (for fast turnaround) or steel molds (for high-volume production), while supporting overmolding or assembly with thermoplastics such as ABS or Nylon.

Below are the key technical specifications relevant to LSR injection molding systems optimized for fast T1 sampling using steel or aluminum tooling:

Parameter	Specification / Detail
Clamping Force	50–300 tons (sufficient for small to medium molds used in prototyping)
Injection Unit Type	Two-plunger metering system for A/B component mixing (1:1 ratio typical)
Shot Size Range	10–200 cc (adjustable for prototype-scale production)
Injection Pressure	Up to 2,000 bar (ensures full cavity fill in intricate molds)
Screw/Plunger Control	Servo-driven metering for precise dosing and repeatable mixing
Mixing System	Static mixer or dynamic blending unit for homogenous LSR compound
Mold Material Compatibility	Aluminum (e.g., 7075-T6 for rapid tooling), P20, H13, or 420 stainless steel for production
Mold Mounting System	Standard HT or HASCO interfaces; quick-change plates for fast setup
Heating Zones	3–5 zones with PID control; barrel temperatures up to 80°C (for LSR processing)
Mold Temperature Control	External chillers or oil-based heaters (20–180°C operational range)
Curing Time	10–60 seconds depending on part thickness and LSR grade
Machine Control System	PLC with touchscreen HMI; recipe storage and process monitoring
Automation Integration	Compatible with robotic mold loading/unloading for lights-out operation
Materials Processed	Liquid Silicone Rubber (addition-cure), with compatibility for overmolding onto ABS, Nylon (PA6, PA66), or other thermoplastics in 2K processes
Cycle Time (Typical Prototype)	45–90 seconds (including clamp, inject, cure, eject)
T1 Sample Turnaround	7 days from mold finalization (requires parallel mold fabrication using CNC-machined aluminum or pre-hardened steel)
Accuracy & Repeatability	±0.05 mm for critical dimensions with aluminum molds; ±0.02 mm with steel molds
Safety Features	Light curtains, mold protection, emergency stop, and material back-pressure control

For rapid T1 sample delivery, aluminum molds are typically used due to faster CNC machining times and sufficient durability for 10,000–25,000 cycles. Steel molds are reserved for longer production runs but can still support a 7-day T1 if pre-hardened steels and high-speed machining are employed. The LSR machine must support fast setup, real-time process validation, and seamless integration with metrology for first-article inspection.

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From CAD to Part: The Process

Honyo Prototype Liquid Silicone Rubber Injection Molding Process Overview

Honyo Prototype executes liquid silicone rubber (LSR) injection molding through a rigorously defined five-stage workflow designed for precision, speed, and technical validation. This process leverages proprietary AI tools and deep material science expertise to mitigate LSR-specific risks such as incomplete curing, flash formation, and material degradation. Below is a technical breakdown of each phase.

Upload CAD
Clients initiate the process by uploading native CAD files (SolidWorks, Creo, NX, CATIA) or neutral formats (STEP, IGES) via our secure portal. Our system performs immediate geometric validation, checking for LSR-critical parameters including minimum wall thickness (≥0.3mm), draft angles (≥1°), and undercuts incompatible with LSR demolding. Files failing validation trigger automated feedback detailing required corrections, reducing iterative delays. All data undergoes ISO 27001-compliant encryption to protect intellectual property.

AI Quote Generation
Validated CAD files enter our AI quoting engine, trained on 12,000+ historical LSR projects. The algorithm calculates material consumption (accounting for LSR’s 3–4% volumetric shrinkage), cycle time (factoring in cure kinetics at 140–200°C), and machine tonnage requirements (80–300T range). Crucially, the AI cross-references real-time silicone batch data (e.g., Shore A hardness variance, catalyst activity) to predict processing stability. Quotes include technical disclaimers for high-risk geometries (e.g., thin ribs <0.5mm) and are human-reviewed within 2 hours for complex medical or optical-grade parts.

DFM Analysis
All projects undergo mandatory Design for Manufacturing (DFM) by senior LSR specialists. This phase focuses on material-specific failure modes:

Critical DFM Checkpoint	LSR-Specific Risk Mitigation
Gate location & type	Validates cold-runner gate placement to prevent premature curing; avoids hot tips for platinum-cure silicones
Venting design	Ensures 0.01–0.02mm vent depth across parting lines to eliminate air traps without flash
Ejection strategy	Confirms ejector pin placement avoids stressing thin LSR features prone to tear
Shrinkage compensation	Adjusts mold cavity dimensions using client-specified silicone grade’s thermal expansion coefficient

DFM reports include mold flow simulation snapshots highlighting potential weld lines or cure heterogeneity, with actionable redesign recommendations. Non-compliant designs halt progression until resolved.

Production Execution
Approved DFM packages move to production in our climate-controlled LSR cell (22±2°C, 45% RH). Key operational protocols include:
Precision metering of Part A/B components via 1:1 volumetric dispensers with ±0.5% accuracy.
Multi-stage curing control: Initial crosslinking at 160°C for 30s, followed by post-cure at 200°C for 4 hours to stabilize mechanical properties.
In-process verification via Shore A durometer checks at T0, T+24h, and T+72h to confirm cure progression per ASTM D2240.
All molds utilize hardened tool steel (HRC 48–52) with PVD coatings to resist LSR abrasion, and are monitored via cavity pressure sensors for flash detection.

Delivery & Traceability
Finished parts undergo 100% visual inspection per ASME B46.1 surface finish standards and dimensional validation via CMM (reporting to ±0.025mm). Each shipment includes:
Batch-specific material certificates (per ISO 10993 for medical grades)
Mold validation data (cavity pressure curves, cure profiles)
Traceability logs linking parts to silicone lot numbers and machine parameters
Parts are packaged in static-dissipative containers with desiccant for moisture-sensitive applications, with global delivery via DHL or client-designated logistics under 72 hours post-approval.

This integrated workflow reduces LSR prototyping lead times by 40% versus industry averages while ensuring first-article compliance for regulated sectors. All stages adhere to ISO 13485 and IATF 16949 frameworks, with full documentation available for audit.

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Start Your Project

Looking for a reliable liquid silicone rubber injection molding machine? Honyo Prototype offers high-performance solutions designed for precision and efficiency. Our machines are engineered to meet the demanding requirements of medical, automotive, and consumer electronics applications.

All equipment is manufactured and rigorously tested at our Shenzhen factory, ensuring superior quality and consistency. We provide full technical support and customization options tailored to your production needs.

Contact Susan Leo today to discuss your project or request a quote.
Email: [email protected]

Partner with Honyo Prototype for advanced LSR molding technology backed by expert engineering and local manufacturing control.

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