Compression Molding
Elimold not only provides compression molding services, but also has extensive experience in the design and manufacture of large to very large compression molds for the plastics industry. Our goal is to be a partner to our customers, providing innovative solutions for complex molding situations. We have a diverse product group team that works together with the customer team from mold concept to the start of production and beyond to ensure the success of each project. Contact us nowhuou
Professional Compression Molding Company
At Elimold, we specialize in manufacturing high-quality custom molded parts for a variety of demanding industries. Our reputation for quality and value has made us a preferred supplier for many commercial and industrial companies. We also offer outstanding flexibility in our manufacturing capabilities; this ensures that the best method is used for your specific application. Our diverse customer base relies on us to provide custom compression molded products.
As an industry-leading contract molding provider, Elimold offers premium compression molding services. For certain projects, using compression molding to produce parts is very reliable and cost-effective. The more parts that can be made per cycle, the lower the cost (the less time required per part).
We pride ourselves on using compression molding to create beautiful and very complex parts. These processes are very flexible and versatile when it comes to solving challenges with certain part shapes. They are also very effective for parts that require exotic materials or difficult to manage inserts.
Our compression molding engineers and designers have extensive experience in redesigning traditional sheet metal or aluminum parts into lightweight composite parts. Often, we are able to compression mold a component that contains 20 different part numbers into a single finished part. Our team of compression molders has begun molding in complex ribs and attachments to save cost and weight while completely eliminating the need for secondary assembly.
Our Compression Molding Capabilities
Elimold can handle compression molding of up to 20 million small products per year. We can make parts from 1 inch to 30 inches in outside diameter. Compression molded plastics can be up to 120 inches in length. Our in-house molding facility has this capability with a 3,000-ton compression molding machine, related equipment, and a dedicated compression molding shop. We are here to support you with mold life. In addition, we can process parts weighing from 0.0005 pounds to 30 pounds at production rates of up to 500 per minute. Our in-house 1 million square foot facility can meet almost any manufacturing process, from prototyping to high-volume production. We use lean manufacturing methods to optimize workloads and minimize waste to reduce costs and increase product value. As a leading compression molding service company, our experts will conduct a comprehensive review of your project to determine if it is suitable for the compression molding process. Partner with us to obtain efficient and reliable compression molding solutions.
Class 10,000 Cleanroom
Our 5,000 square foot custom compression molding cleanroom is equipped with HEPA filters, room pressure monitoring, airflow monitoring, and constant temperature and humidity control to meet the industry’s demand for high-quality molded elastomers.
All cleanroom processes involved in manufacturing your custom components are performed in our cleanroom, including: custom material compounding, molding, cleaning, quality inspection, customer-specified processing, sub-assembly, and special packaging.
Types of Compression Molding
Elimold offers a wide range of custom compression mold manufacturing services. Our team is not limited to any one compression molding process; instead, we are able to leverage our experience and capabilities in different molds through the use of compression mold tools, which allows us to be more flexible in approaching problems. We can package injection molded parts or components into high-pressure core-shell molding processes with excellent results.
Matched Tool Forged Fiber
Compression-molded composites are also known as forged composites. Matched metal tooling is necessary for this process, making it ideal for high volume part production.
Autoclave Molding
Autoclave molding is a process used to impart a controlled heat and pressure cycle cure to a layup. Additional pressure permits higher density and improves inter-layer adhesion.
Vacuum Bag Molding
Vacuum bagging is a flexible process that is used to manufacture laminated structures. It produces a uniform degree of consolidation while removing entrapped air through vacuum pressure.
Infusion Molding
Infusion molding is a technique where voids in a stack of porous material (e.g. carbon fiber) are filled with a liquid resin. When the resin solidifies, the solid resin matrix binds the assembly of materials into a unified rigid composite. This is a highly efficient closed mold process.
Bladder Molding
Bladder molding begins with composite material being applied to a bladder and the part is inserted into a female cavity mold. A press is used to close the mold and heat is applied to cure the part. Air pressure is used to force the laminate outward in the cavity, consolidating the material in the closed mold.
Custom Compression Molding Manufacturer
Elimold offers a comprehensive range of compression molding services, providing customers with reliable and cost-effective solutions for producing high-quality parts for a wide range of applications. Our company’s expertise in material selection, mold design, and process optimization, combined with its state-of-the-art equipment and commitment to quality, make it a trusted partner for businesses seeking superior compression molding results.
Our highly automated and efficient plastic part compression molding manufacturing capabilities mean you can get your product in the quantities you need, fast. We specialize in fast turnaround times, reducing lead times from weeks to days. Best of all, our free and highly accurate quote process is the fastest in the industry. So, no matter what type of product you need, Elimold has the expertise and capabilities to meet your specific needs. By choosing Elimold, you gain a partner committed to quality, innovation, and customer satisfaction in every compression molding project.
Our Compression Tool Manufacturing Capabilities
If you are looking for a compression mold manufacturer, contact Elimold for high quality, competitively priced compression molding tools. At Elimold, we focus on getting the job done right the first time. Whether it is a simple or complex part, our years of experience can help you build a compression mold that will provide the highest quality parts at the lowest production cost.
We have the ability to build single and multi-cavity compression tools for molding substrates, composites, thermoforms, and thermoset sheets. Our compression molds are designed to compress substrate layers in one pass and trim the edges of the finished product. Elimold builds simple to complex single and multi-cavity molds with a maximum weight of up to 10 tons. We are experienced in building complex multi-slide compression molds that require precise tolerances. We can handle custom molds up to 35x41x79 inches (or up to 20,000 pounds) with tolerances held to within (±) .0005 inches. Elimold always provides excellent custom mold manufacturing services.
Our Compression Mold Design Engineer Capabilities
At Elimold, we have a full-time team of design engineers working alongside highly trained CAD/CAM programmers. All design and machining is done in-house, which allows us to keep costs down while still maintaining the high quality your parts require. We leverage our internal network to maintain a seamless workflow to maximize efficiency and reduce cycle time to provide you with quality compression molds for your plastic part manufacturing.
Our in-house design engineers will work with you to custom a mold that best fits your plastic part manufacturing needs. Our commitment to quality work is only fulfilled when your business is able to manufacture the quality parts your customers demand. In addition to design, our engineers can also help you update molds you already have.
Enhanced Design Flexibility for Compression Molding
Designing parts with complex geometries in compression molding is challenging due to process limitations. Mold shape and size must be carefully considered, as undercuts and complex features can complicate manufacturing. Elimold uses advanced mold design techniques to increase versatility. Computer-aided design (CAD) software allows for accurate simulations, predicts performance, and ensures specifications are met. A collaborative design process helps make adjustments to meet molding capabilities while maintaining functionality and aesthetics.
Compression Molded Part Prototyping
Our innovative engineering team will actively participate in the design phase of rapid prototyping of your product, then validate it through functional testing and most importantly, production testing. Every product that goes through our engineering process is guaranteed to be production-ready. Whether it is tool prototyping, functional testing, or providing fused deposition modeling, CNC machined prototypes, or single-cavity prototype molds, we can ensure that your prototype components have more than just the look and feel of a custom compression molded plastic part. Our prototype tools are able to go into production once the design is complete.
Ready to start your next compression molding project?
Elimold can help you take your idea from design to market. Use our instant quote system to find out if your design is a good candidate for compression molding. Our experts will review the design and let you know if the part can be manufactured using compression molding. Design reviews are typically completed within one business day. We look forward to working with you.
Custom Compression Molding Contract Manufacturing Capabilities
Our custom contract manufacturing capabilities provide custom solutions to meet the specific needs of your business. With advanced technology and flexible methods, we provide high-quality, cost-effective production services for a wide range of products. Whether you need small-scale or large-scale manufacturing, we work closely with you to ensure that the final product meets your exact specifications and delivery deadlines. And, our highly skilled engineers will work closely with you to provide a tailored solution based on your specifications. As a top global compression molding manufacturer, we ensure that you have access to the best materials for your compression molded products. We start by evaluating your requirements, design specifications, and timelines so that we can find the most effective way to enhance your compression molded products. From design and material selection to labeling, we will guide you through every stage until your product is ready for release.
Compliance for Compression Molding Services
Compliance for Compression Molding at Elimold involves stringent monitoring and control to ensure precise adherence to industry standards. The materials used undergo extensive testing to meet regulatory requirements for performance and safety. Advanced process controls guarantee consistency and reliability in every part. Elimold focuses on precision and accountability throughout all manufacturing stages, ensuring compliance with critical specifications.
- ISO 9001:2015
- RoHS
- REACH
- FDA 21 CFR Part 820
- UL 94
- ISO 14001:2015
Rigorous Quality Control
Elimold always makes your complete satisfaction our top priority. We continually strive to improve our manufacturing processes and quality control protocols, ensuring you receive the best products and customer service with every order. As your preferred compression molded parts manufacturing problem solver, we are ready to solve any application, request or question you may have regarding custom compression molding services. When we say quality conscious, we mean more than just our QA team. We mean every member in the production department, engineering department, mold shop and even the warehouse.
Compression Molding Service Materials
As a professional on-demand manufacturer, Elimold offers various compression molding materials to satisfy customer’s requirements. Some of the materials available for compression molding are as below. We also offer material modification services. Our professional material engineers will adjust the raw material formula to meet the unique conditions of use and the special needs of the customer.
- Silicone (varying durometers)
- Optical-Grade Silicone
- Medical-Grade Silicone
- Fluorosilicone
- Urethane
- High-density Polyethylene
- Epoxy
- Melamine
- Polytetrafluoroethylene (PTFE)
- Polyphenylene Sulfide (PPS)
- Neoprene
- Butyl
- Polypropylene
- Polystyrene
- UHMWPE
- EPDM
- Viton
- Nitrile
- Nylon
- Butyl
- Phenolics
- PEEK
- Nylon
- TPR
- NR
- SBR
- CR
- VMQ
- FFKM
- NBR
- IR
- FKM
Experience in Custom Compounding
With decades of experience, our chemical experts can develop custom plastic compounds to meet your specific requirements. Each batch is tested and approved before it goes into production. Standard testing for each batch includes rheological and physical properties. These tests are checked against the limits set to approve or reject each compound. Tests requested by the customer or critical to the functionality of the molded product are continuously monitored in our laboratories. To ensure the consistency of the compounded material, our chemical experts analyze statistically organized data collected by our software programs.
Value-Added Services
In addition to compression molding, we can provide many value added services to enhance the design and development process. These include rapid prototyping, engineering and design consulting, CAD/CAM, standard molding and test samples. Whatever the design considerations or complexity challenges, at Elimold we offer a comprehensive range of in-process, secondary and finishing operations that can meet your specific requirements. Our services include drilling and tapping, post-curing, bonding, testing, CNC machining, and assembly and sub-assembly. As a result, Elimold can meet all of your compression molding needs, providing excellent service at every stage of the manufacturing process.
Compression Molding Surface Treatments
Compression molding surface treatments will improve the quality of your plastic molded parts. Elimold offers a wide range of surface treatment options. These highly effective surface treatments can improve the functionality and aesthetics of your parts.
Glossy
A-grade finish is smooth and highly reflective, giving the product a shiny appearance. It’s often used for products where aesthetics are important.
Semi-glossy
The B-grade finish is less reflective than glossy but still has a smooth and somewhat shiny appearance.
Matte
C-grade finish is non-reflective and has a dull appearance. It’s often chosen for parts where glare or light reflection is undesirable.
Textured
D-grade finishes are intentionally rough or patterned. They can provide a better grip or a unique appearance to the product.
Compression Molding Surface Finishing
From smooth and glossy to textured and matte finishes, we offer a range of surface treatments to meet your design preferences. We primarily offer SPI finishing, VDI is also available is needed.
- SPI A1: 6000 grit diamond, surper high glossy finish
- SPI A2: 3000 grit diamond, high glossy finish
- SPI A3: 1200 grit diamond, normal glossy finish
- SPI B1: 600 grit paper, fine semi-glossy finish
- SPI B2: 400 grit paper, normal semi-glossy finish
- SPI B3: 320 grit paper, normal semi-
- SPI C1: 600 grit stone, fine matte finish
- SPI C2: 400 grit stone, medium matte finish
- SPI C3: 320 grit stone, normal matte finish
- SPI D1: Dry blast glass bead, satin textured finish
- SPI D2: Dry blast, dull textured finish
- SPI D3: Dry blast, rough textured finish
Post-Molding Services
- Deflashing
- Drilling
- Epoxy
- Gluing
- Machining
- Metal Insertion
- Metallizing
- Painting
- Post bake
- Potting
- Tapping
Industries Served
- Appliance
- Aerospace
- Batteries
- Defense
- Electrical
- Food & Beverage
- Fracking & Oil Field
- Housewares
- Lighting
- Medical
- Outdoor Grills
- Park & Recreation
- Pumps
- Restaurant
Compression Molded Parts in Various Industries
Compression molding services are used in a wide variety of industries, especially those that require high-volume production of durable, precision parts. Many industries benefit from our compression molding services, and no matter what type of plastic part you need, we can provide efficient and reliable solutions.
- Rail Industry: Elimold manufactures custom rubber parts for the rail industry that are safe and compliant with government regulations. This includes bellows, cable cleats, electrical insulators, sand nozzles, and custom grommets.
- Mining: We serve companies across the mining industry by manufacturing rubber parts such as engine mounts, gaskets, flexible connectors, vibration isolators, bumpers, and much more.
- Construction: Elimold provides custom rubber parts for applications in the rail industry, including bellows, grommets, gaskets, bumpers, and more.
- Vibration Control: We provide rubber parts for applications in vibration control, including a variety of mounts, spring cups, bushings, anti-vibration pads, and more.
- Oil & Gas: In the oil and gas industries, Elimold provides custom rubber parts including gaskets, grommets, seals, and more.
- Pet Products: Elimold manufactures safe products for your pets, including an assortment of dog toys. All of our pet products are safe, using only FDA-compliant ingredients. We also provide full service capabilities, including design, manufacturing, and packaging services.
Other Molding Processes
We also offer other types of plastic molding services that differ from compression molding in that the plastic is melted and injected into a molding tool. This process is typically used to produce small to medium-sized orders of plastic parts. Elimold is a full-service plastic molding company, so you can be confident that our plastic molding engineers and designers have extensive experience in producing parts from a variety of composite plastic materials.
Plastic Injection Molding
LSR Injection Molding
Overmolding
Gas Assist Injection Molding
Insert Molding
Structural Foam Molding
Rapid Tooling
Micro Molding
Production Tooling
What is Compression Molding?
Compression molding is a manufacturing process that uses pressure to shape a part. A heated rubber material is placed on one side of the mold. The other side of the mold is then clamped, compressing the rubber material into the desired shape. The mold must be heated because the combination of compression and heating is what causes the rubber to form into a new shape. The design of the mold must also meet certain standards for compression manufacturing. Compression molds need to have overflow grooves to allow excess material to flow out of the mold. It is difficult to accurately predict the amount of rubber material required without any overflow. Using a little extra material will ensure that the mold is completely filled and the product comes out as expected. The excess material is called flash and must be trimmed after the compression molding is complete.
Advantages of Compression Molding
Cost is one of the driving factors in the popularity of compression molding. Compression mold tools are much less expensive than tools for similar processes such as injection molding. Compression molds are much less complex and require fewer machine hours. Compression molds do not require the gates and runners required for injection molding.
The thickness of compression molded parts can vary without problems. Parts as thin as 0.5 mm (0.02 in) or as thick as 25 mm (1 in) are easily produced. Designers are able to specify seamless design features with compression molding. There are no flow marks or weld lines to worry about that may occur with injection molding.
Differences between Compression Molding and Injection Molding
Compression molding and injection molding are similar, but there are several key differences. These differences will influence your decision to choose the best process. Compression molding uses heat and pressure to form a shape within a mold. Injection molding, as the name implies, is the pouring or injection of hot material into a closed mold.
Injection molding is better suited for objects that require intricate details (such as threads or ribs), thin walls, or complex parts. Compression molding wins when it comes to thicker products that require strength, solidity, and durability. Overall, injection molding processes tend to be faster than compression molding processes.
Request Your Free Compression Molding Quote Today
After receiving your drawings, our engineers will analyze your custom Compression Molding parts right away. We actively work with you to clarify all details before providing a quote that is both economical and accurate.