In recent years, more and more consumers have been attracted by the eco-friendly, safe, and non-toxic characteristics of silicone products, making silicone products highly frequent in daily life. Silicone, with its eco-friendly, soft texture, safety, non-toxicity, and chemical stability, has led to an increasing number of products being made from silicone. The types of silicone we commonly see are industrial-grade silicone, food-grade silicone, and medical-grade silicone. For companies developing new products, it is very important to choose a professional and suitable silicone OEM factory. Below, we introduce the professional knowledge and custom process of silicone OEM.
What is Silicone?
Silicone, in English, is Silicone. It is derived from silicon ore to extract silica, and is a highly active adsorbent material. It is insoluble in water and any solvents, non-toxic, odorless, and chemically stable, not reacting with any substances except for strong alkalis and hydrofluoric acid. Silicone forms different structural characteristics due to different manufacturing methods. Its features include: high adsorption performance, good thermal stability, chemical stability, and high mechanical strength. Silicone’s waterproof and insulating properties also meet industrial sealing and pressing needs, ensuring product stability. In terms of temperature resistance, silicone can withstand temperatures ranging from -40°C to 230°C.
Silicone products can be divided into inorganic silicone and organic silicone based on their properties and composition. Organic silicone is an organic silicon compound, commonly referred to as a “composite” new material created by chemists combining silicon from quartz sand with organic macromolecules. Organic silicone possesses the characteristics of both inorganic substances and organic materials, capable of performing tasks that other materials find difficult. Inorganic silicone, scientifically known as “silicon dioxide micro-powder,” is an amorphous product made from sodium metasilicate and sulfuric acid in silica soil. Inorganic silicone can be further divided into fine-pore silicone, B-type silicone, and coarse-pore silicone, usually in transparent or milky white granular solid form, and is a high-activity adsorbent material.
Difference Between Silicone, Rubber, and Plastic
Rubber, in English, is Rubber. It refers to a high-elasticity polymer material with reversible deformation. At room temperature, it is elastic, and under small external forces, it can deform greatly, returning to its original state once the external force is removed. Rubber is a completely amorphous polymer with a low glass transition temperature (Tg) and typically has a large molecular weight, often greater than several hundred thousand. Rubber is generally classified into natural rubber and synthetic rubber. Natural rubber is derived from the latex secreted by the rubber tree, which is solidified and processed, accounting for about 40% of production. Synthetic rubber, based on natural gas, coal, and petroleum, is obtained through chemical methods to produce monomers, which are then polymerized into highly elastic polymer compounds within a specific temperature range, serving as a substitute for natural rubber, and accounting for about 60% of production.
Plastic, in English, is Plastics. It refers to synthetic resins with high molecular weight as the main component, combined with appropriate additives such as plasticizers, stabilizers, flame retardants, lubricants, and colorants, which solidify into a shape upon processing. During the manufacturing and processing stages, they can be molded by flow. The processed material can be a flexible (ductile) material or a rigid material formed by curing or crosslinking. Based on the various physical and chemical characteristics of plastics, they can be divided into thermosetting plastics and thermoplastic plastics. Thermosetting plastics require curing to solidify during molding, such as phenolic, urea-formaldehyde, melamine formaldehyde, epoxy, and unsaturated polyester plastics. Thermoplastic plastics melt when heated, such as nylon (Nylon), polyethylene (PE), polypropylene (PP), polyvinyl chloride (PVC), acrylonitrile-butadiene-styrene (ABS), polystyrene (PS), polyoxymethylene (POM), polycarbonate (PC), polyurethane (PU), and polytetrafluoroethylene (PTFE, Teflon).
The Difference Between Silicone, Plastic, and Rubber
Over a decade ago, silicone products began to gain popularity but were often mistakenly identified as plastic or rubber products. The emergence of silicone products was aimed at replacing the polluting plastics and rubbers. The biggest difference between silicone and the latter two is that plastic and rubber products release toxic substances when heated, while silicone’s toxic components are completely released and removed during the production process, and silicone itself can withstand high temperatures up to 230°C. Plastic and rubber have a limited lifespan and will become hard and brittle after use for some time. Silicone, being safe and durable, can significantly reduce resource consumption.
Silicone OEM Customer Process
Silicone is a type of organic silicon product that has excellent high and low-temperature resistance, UV resistance, radiation resistance, weather resistance, electrical insulation, high permeability, physiological inertness, low permanent deformation under compression, and fatigue resistance. As a result, silicone is widely applied in aerospace, aviation, electronics, electrical, light industry, machinery, construction, chemical engineering, medical, daily use products, food processing, and more. Silicone processing methods include molding, injection, extrusion, calendering, mold casting, and drop molding.
Silicone OEM Production Process:
The silicone OEM production process involves a series of steps such as mold creation, material inspection, material selection and mixing, rubber mixing, cutting, molding (molding, liquid, extrusion, drop molding), processing/backing/pressing, secondary vulcanization, printing/spraying, laser engraving, full inspection, quality assurance, packaging, and shipping.
1. Mold Creation
The mold design and production are based on the 3D design files to be manufactured.
2. Material Inspection
Silicone raw materials to be used are purchased based on product characteristics, and quality inspection is performed on the materials upon arrival to ensure the performance meets the required quality standards.
3. Material Selection and Mixing
Choose the necessary additives, such as curing agents, colorants, and other additives, in addition to the raw materials.
4. Rubber Mixing
Silicone raw materials are typically in block form, generally milky white. At this stage, the raw materials cannot be directly molded by heat and pressure and must have curing agents (maturing agents) added. If the product has special requirements, such as color, glow-in-the-dark, fluorescent, phosphorescent, or conductivity, corresponding additives like colorants, phosphorescent powders, fluorescent powders, and conductive particles are also needed. The raw materials, curing agents, and other required additives are mixed together using a rubber mixer, with the mixing time typically around 30 minutes (depending on the raw material weight and roller gap).
5. Cutting
The mixed silicone raw material is cut to the desired silicone dimensions (length * width * thickness). The cut raw materials are then placed on a material resting rack to sit for a period of time, typically around 8 hours. Both sides of the raw material are protected with a PE film to ensure cleanliness.
6. Molding
After the resting period, the silicone material is molded using methods such as molding, liquid molding, extrusion, or drop molding.
There are two main types of high-temperature silicone available in the market: solid silicone and liquid silicone. Solid silicone molding can be further divided into heat press molding and extrusion molding, while liquid silicone is typically molded via injection molding or drop molding.
Common Molding Techniques Used in Silicone OEM Customization
1. Solid-State Heat Press Molding
This technique utilizes the temperature and pressure of a hydraulic press, assisted by a mold, to vulcanize and mold the product. This method is primarily used for single-color silicone customized products. It can also be applied to dual-color, dual-hardness silicone products or multi-color, multi-hardness products, including plastic and metal encapsulation, where the encapsulated items have temperature requirements, typically requiring the encapsulated items to withstand temperatures of 180°C without deformation. The molded silicone product can withstand temperatures of up to approximately 230°C.
2. Liquid Injection Molding
This technique is suitable for the injection molding process of two-component, semi-transparent liquid silicone rubber materials. Liquid silicone injection molding is typically done by curing liquid silicone with excellent properties and then combining it with equipment capable of precise and stable injection molding, forming a new processing system. The injection molding of liquid silicone requires loading both A and B liquid materials into the equipment. The entire process, from mixing to molding, is fully automated, simplifying the process and reducing processing time while ensuring high-quality customized liquid silicone products. The curing temperature for liquid silicone molding is generally between 110°C to 150°C, so the embedded items must withstand temperatures of at least 150°C to avoid deformation.
3. Extrusion Molding
Similar to commonly seen water pipes, extrusion molding refers to the process where the material passes through the extrusion machine’s barrel and screw, heating and curing as it moves forward, and continuously passes through the die to form various cross-sectional products or semi-products. The extrusion die determines the product’s cross-sectional shape and has a certain length. Under the influence of force and temperature, the product is already cured and formed as it exits the die. This process is commonly used to produce customized silicone products in strip form, with various cross-sections. Examples include rectangular strips, ring-shaped silicone tubes, etc.
For solid silicone, common hardness ranges from (Shore hardness) 30A to 70A, while liquid silicone typically has a hardness of (Shore hardness) 0A to 70A. Liquid silicone with a hardness lower than Shore 0A is also available but requires customization. These must be measured using a Shore C durometer. Liquid silicone can also be produced with hardness levels of 80-90A, but this will be more brittle and is not commonly used. For hardness levels higher than 90A, a Shore D durometer is used. This type of silicone is very hard but has minimal elasticity.
In general: When silicone hardness is below 10A, the tear strength is low, elongation is high, and silicone products are prone to deformation. When hardness exceeds 40A, tear strength decreases, and silicone products become brittle, easily breaking or cracking. The best tear strength and elongation occur with silicone hardness between 20-40A. Common silicone hardness for everyday items like silicone bowls, mats, and tubes is typically (Shore hardness) 50A to 70A.
Common Uses of Silicone OEM Products
1. Silicone OEM for the Electronics Industry
The electronics and electrical industries were the earliest and largest users of silicone as an insulating material. This is mainly because high-temperature vulcanized silicone rubber is resistant to extreme temperatures, has excellent electrical properties, and maintains its performance across a wide temperature range and electrical frequency spectrum. Silicone products made from high-temperature vulcanized silicone ensure the stable, safe, and reliable performance of electronic and electrical devices. Products include electrical connectors, sealing and shock-absorbing components, high-temperature potentiometer seals, and more. Silicone rubber enhanced with conductive fillers (such as carbon black or metal powders) can be used for conductive components (such as buttons for computers, remote control systems, electric toys, telephones, and conductive connection pads for electronic watches). Conductive silicone is also widely used in microwave ovens, fax machines, and leadless integrated circuits. Televisions also use many silicone components, with silicone being used to make high-voltage caps for TVs. Silicone insulators are gradually replacing ceramic components in transmission lines, particularly in ultra-high-voltage circuits. Conductive silicone is also used for electrical contact points in computers, telephones, and other instruments, as well as LCD display contacts. Fire-retardant and radiation-resistant silicone products are widely used in atomic power stations. Silicone heating plates and heating tapes control the working temperature of precision instruments and oil pipelines, as well as being used in medical therapy heating blankets.
2. Silicone OEM for the Automotive Industry
Silicone applications in the automotive industry are growing rapidly. Silicone materials (especially those with various characteristics) are resistant to fuel and lubricants, improving the performance of automotive components and reducing maintenance costs. They can be used in spark plug protectors, ignition wires, heating and radiator hoses, muffler linings, battery terminals, and fuel pumps made with fluorosilicone. Components near engines and transmissions, such as bushings, gaskets, belts, protective covers, caps, and seals, require resistance to temperatures up to 175°C, while some areas may need to withstand temperatures above 300°C. In these cases, conventional organic rubbers are not suitable, and silicone is required. Silicone is also used in sealing high-temperature furnaces, low-temperature refrigeration box structures, metal processing conveyors, and heating glue radiators.
3. Silicone OEM for the Food Processing Industry
Food-grade silicone is made from newly imported, food-grade silicone raw materials using scientific manufacturing processes, making it highly adaptable. It has high transparency, no odor, no yellowing, and no frosting. Food-grade silicone is an addition-type silicone with high transparency and stability, capable of withstanding temperatures up to 230°C without degradation in a sealed environment. The product is soft, heat-resistant, and stable. In today’s health-conscious world, food-grade silicone is gradually replacing food-grade plastics. Products made from food-grade silicone are typically used for items in direct contact with the human esophagus. Common food-grade silicone products include silicone tubes, mats, sheets, and silicone-clad tubes for the food processing industry, which are phthalate-free and commonly used in most food processing plants. Silicone is widely used in coffee makers, water heaters, bread machines, sterilizers, water dispensers, electric kettles, rice cookers, deep fryers, fruit juice machines, and other mechanical products. It is also used in molds for food, chocolate molds, candy molds, cake molds, and silicone ice trays.
4. Silicone OEM for Maternity and Baby Products
Silicone is an environmentally friendly material, and baby products are made from food-grade certified silicone materials. These materials exhibit excellent properties, with high stability, temperature resistance ranging from 40-230°C, and ease of cleaning. Silicone products have a certain degree of elasticity and toughness, ensuring they do not deform, age, or break easily, making them more adaptable to various conditions such as oil stains, freezing, or high temperatures. Many baby products are made of silicone, including the most common silicone nipples, baby bottles, bibs, teething toys, teething sticks, silicone spoons, and silicone baby lunchboxes.
5. Silicone OEM for the Medical and Health Industry
Silicone is non-toxic, biocompatible, and has excellent physical and mechanical properties, including high-temperature sterilization resistance. Its biocompatibility ensures minimal body reactions, and its stable performance and low blood coagulation make it suitable for medical applications. It can endure multiple sterilization cycles at high temperatures and pressures, and can be processed into various shapes like films, sponges, and airbags. Silicone is widely used in medical devices, including transfusion tubes, various catheters, chest drainage tubes, cosmetic repair materials, artificial skin, implantable devices, drug release systems, biosensors, and more. It is also used to create artificial organs such as artificial throats, lungs, retinal implants, artificial heart valves, esophagus, trachea, artificial joints, and prosthetics. Silicone medical devices help restore functions like speech, eating, and breathing for patients who have had their larynx removed. In the medical field, silicone applications can be categorized into long-term implants, short-term
6. Silicone OEM for the Wires and Cables Industry
Silicone is an ideal insulating material for the wires and cables industry. High-temperature vulcanized silicone rubber is resistant to high temperatures, ozone, weathering, and has excellent electrical properties. When silicone burns and decomposes, the silica residue still serves as an insulator. Silicone also has excellent thermal conductivity, allowing it to quickly dissipate heat generated by electrical currents. Its arc resistance is exceptional. High-temperature vulcanized silicone is used in power cables, ship cables, heating cables, ignition cables, atomic energy cables, and aviation wires. Silicone used in high-voltage insulation wires is enhanced with aluminum hydroxide fillers to improve leakage resistance, electrical erosion resistance, and electrical arc resistance.
7. Silicone OEM for the Aerospace and Aviation Industry
Aerospace and aviation materials must endure long-term operation in temperatures ranging from -75°C to 200°C, with resistance to ozone, radiation, aging, and combustion. Silicone is an indispensable high-performance material in the aerospace industry. Silicone materials can withstand the extreme cold of space and the intense heat of atmospheric reentry, extending the lifespan of aircraft parts, reducing maintenance costs, and decreasing accident risks. Silicone is primarily used in airplane body sealants, electrical connectors, sealing switches, dust and waterproof covers, gaskets, O-rings for jet engines and hydraulic devices, oxygen masks, regulating diaphragms, heat air ducts, and radar shock absorbers. Fire-resistant silicone is used for rocket fuel valves, power source cables, and rocket launch pad coatings to protect against burns from rocket exhaust. Silicone products commonly used in this field include various hoses, sealing gaskets, washers, bellows, valves, shock absorbers, heat air ducts, switch covers, oxygen masks, fire barriers, and soft hoses for instruments and meters.
8. Silicone OEM for Other Industries
Silicone films made from high-temperature vulcanized silicone have excellent breathability, with permeability several times greater than that of other high polymers like polyethylene, PVC, and PTFE. Silicone films also exhibit selective permeability, allowing for the creation of various silicone air-adjusting windows for fresh-keeping bags or storage rooms for vegetables, fruits, and food. Silicone is also used in sealing components such as those for printing press rollers, pressure cooker gaskets, and other visiting tools.
Silicone OEM Custom Development Process
Silicone OEM Process 1: Confirming Requirements
Once the client has a clear idea for the product being developed and provides the engineering 3D drawings (Stp, Step, Igs file formats), we will assess the feasibility of silicone customization development based on these 3D drawings. We will also discuss closely with the client and assist with design. In order to provide professional advice, especially when selecting raw materials, we must clearly understand the client’s design concepts and intended use. For example, if the silicone product is for food processing, temperature and food safety requirements dictate the use of food-grade silicone. For custom industrial silicone products, since the product may be subject to frequent usage or external collisions, the material must be flexible and wear-resistant. We will choose raw materials that meet these specific properties.
Silicone OEM Process 2: Provide Quotation
We will assess the production method (e.g., solid-state hot pressing, liquid injection molding, or extrusion molding) based on the product characteristics. Key evaluation points include (1) 3D drawing feasibility for mold opening, (2) quantity required, (3) time requirements, (4) budget. For customized products, we evaluate the mold fees for sample molds, production molds, and product unit prices.
Silicone OEM Process 3: Confirming Order
If the client approves the quotation, they will prepay mold fees and a deposit according to the quoted terms.
Silicone OEM Process 4: Mold Sample Opening and Sampling
We open sample molds based on the product’s type, color, hardness, quality, and quantity requirements. After the silicone product sample is finished, the engineering team compares it with the client’s requirements and confirms that it meets the client’s expectations before submitting the first batch of samples. The client evaluates the sample, and if it meets the standards, they approve mass production. If the sample doesn’t meet the requirements, the client will provide feedback, and we will modify or remake the sample until the client is satisfied.
Silicone OEM Process 5: Opening Production Molds
After confirming the sample, production molds are opened. The number of mold cavities depends on the product’s size and quantity. For large quantities, multiple molds may be needed for simultaneous production to meet the client’s deadlines. Silicone product pricing isn’t as simple as it seems and requires understanding more details to offer the best cost-effective solution. After mold processing, a trial molding is conducted, and the mold may need to be modified before mass production.
Silicone OEM Process 6: Mass Production
Once the production molds are opened, molding operators begin mass production of the client’s silicone custom products, producing in shifts until the current order is completed.
Silicone OEM Process 7: Post-Processing
After mass production of silicone products, additional post-processing steps are required, such as burr removal, printing, spraying, laser engraving, labeling, and surface treatment. These processes can add functionality and value to the silicone products, such as branding with logos, laser engraving, or adding a soft touch with spray coating.
Silicone OEM Process 8: Deburring and Quality Inspection
After removing burrs from the silicone products, quality inspection is conducted to ensure the product matches the standard without defects like burrs, stains, or other flaws. Any defects found will be analyzed and promptly resolved to ensure all products shipped are in good condition.
Silicone OEM Process 9: Packaging and Shipping
After completing the silicone custom products, they are packaged according to the client’s requirements. Upon receipt, clients should inspect the products and store them. If any quality issues are found, clients should notify us for immediate resolution. After successful inspection, the order is considered complete.
Conclusion
Dafeng Manuacturer focuses on customized silicone OEM development. The production process has passed the international ISO9001 certification. The silicone raw materials provided by Dafeng Zhengye meet FDA and LFGB food-grade standards and have been tested by Taiwan SGS. With well-known clients in the industrial, electronics, food processing, and medical equipment sectors, Dafeng Zhengye is a professional silicone OEM factory and silicone manufacturer in Taiwan, providing the most suitable product development services.
