Compression Molding
Composite parts, compression molded for cost and weight savings.Our team has the capabilities to mold large, intricate parts for you with low-cost tooling and minimal waste, so you get high-quality products without high costs.
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 handles compression molding of up to 20 million small products per year. We can manufacture parts from 1″ to 30″ outside diameter. Compression molded plastics can be up to 120″ in length.
As a leading compression molding service company, our experts will conduct a thorough review of your design to determine if it is suitable for rubber compression molding. Partner with us for an efficient and reliable compression molding solution.
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.
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 prototyping and test samples. Regardless of the design considerations or complexity challenges, our ISO 9001:2015 certified molding services can improve your bottom line without compromise.
Compression Molding from Prototyping to Production
Rapid Prototype
Our rapid prototyping service uses 3D printing and CNC machining manufacturing processes to quickly prototype within days. Ensure your molded products are launched as quickly as possible.
On-demand Manufacturing
Elimold on-demand production meets your needs and allows your custom products to be produced efficiently and quickly at competitive prices.
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.
Elastomer and Rubber
Elastomers and rubber are common materials for the compression molding process.
- NR
- SBR
- CR
- VMQ
- FFKM
- NBR
- IR
- FKM
- EPDM
Plastic Materials
Thermosetting plastic materials can be used for the compression molding process because of their excellent heat resistance and dimensional stability.
- UHMWPE
- PTFE
Thermoplatic-Rubber
Thermoplastic elastomers(TPEs) with excellent elasticity, flexibility, and resilience.
- TPE
- TPV
- TPU
- TPR
Surface Finishing
Proper surface finishing will improve the molded parts’ quality. Elimold offers a wide range of surface treatment options. These efficient surface finishes improve the part’s functions and aesthetic appeal.
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.
Textured
D-grade finishes are intentionally rough or patterned. They can provide a better grip or a unique appearance to the product.
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.
Semi-glossy
The B-grade finish is less reflective than glossy but still has a smooth and somewhat shiny appearance.
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
- Enhanced properties compared to other manufacturing methods
- Higher tensile strength
- Greater elongation
- Increased hardness
- Improved toughness
- Greater dimensional stability
- Lower coefficient of friction
- Enhanced dielectric properties
- Minimized internal stress and warping
- Excellent dimensional stability and machining accuracy
- Near-net molding limits scrap, which saves money, especially when molding expensive plastic compounds
- Large, bulky parts can be molded
- Ability to manufacture large basic shapes that cannot be made using extrusion techniques
- Ability to mold polymers that are inherently not well suited for other processing methods
- Ability to produce custom blends
- Reduced mold costs—we have hundreds of mold sizes in stock
- Low minimum quantities allow you to order just what you need without having to pay for expensive tooling or small-run setup charges
- For prototypes or small quantities, machining compression-molded plastics is a cost-effective alternative to building expensive molds
Industries & Applications
Compression molding is suitable for many industries because it can produce parts of various lengths, thicknesses and complexities. At Elimold, we compression mold nearly any type of organic or synthetic rubber compound for the following industries:
Industries that rely on our custom compression molding capabilities include:
- Aerospace
- Appliances
- Automotive
- Diagnostics
- Industrial
- Laboratories
- Medical devices
- Personal Care
- Pharmaceutical
Dental and Medical
Each compression molded part is safe for skin-sensitivity issues and can withstand constant sterilization. Common compression molded products for the dental/medical sector include:
- Respirator masks
- Precise & uniform flow control valves
- Gaskets
- Syringe stoppers
Consumer Products
Compression molding at Elimold creates long-lasting, cost-efficient consumer parts and products in a range of shapes and sizes, such as:
- Keypads
- Spatulas
- Shower heads toys
- Buttons
- Switches
- Handles
- Gaskets
- Cookware
- Household products
Food & Beverage
Our compression molded parts are FDA-compliant, food-grade, and built for the heavy demands of high performance equipment. Common food and beverage applications include:
- Low-creep industrial gaskets, seals, and O-rings built to withstand exposure to food processing, transportation, and preparation
- Hoses and tubes optimized for food & beverage environments
- Bottle dispensers and nozzles with superior precision and liquid-flow management features
Specialty Applications
Tight tolerances and demanding timelines are no problem at Elimold, and our HCR and liquid silicone can be molded for resistance to harsh environments, precision, and flexibility. Specialty applications include:
- Sealants
- Gaskets
- Nozzles
- Pressure membranes
- Spark plugs
- Engine components
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