Rubber Product Manufacturing Processes
How is rubber manufactured? This is no simple question.
The process of rubber manufacturing dates back well over a century, to the earliest compression molds of the 1890s. The rubber manufacturing process has undergone considerable developments since then.
Today’s rubber product manufacturing technology blends time-honored best practices with modern production advancements. Rubber product manufacturers can choose from a range of manufacturing methods to create everything from simple shapes to complex components destined for secondary processes and rigorous service environments.
So, how is rubber manufactured? Below are some of the most common rubber manufacturing processes.
Die Cutting
Die cutting is a rubber manufacturing process that uses a shaped blade called a die to create identical cuts in a rubber material. A die may cut a whole shape, such as a washer or gasket, from a sheet of rubber or create a hole or slit in a larger shape. There are many different types of die cutting machines available, such as slitters, flatbed cutters, beam presses, and CNC machines.
Die cutting is an excellent option for simple shapes produced in high volumes and cut from rhino to medium-thickness material. Common examples include seals, washers, gaskets, pads, and sheets, as well as novelty items, such as keychains or toys. The die can be used over and over, which can reduce tooling costs.
Plastic Extrusion
The plastic extrusion process begins with heated plastic material. The material is then forced through a specialized opening to create a long, continuous profile of a 2D shape. The third dimension is the length to which the profile is eventually cut.
Plastic extrusion is a quick, cost-effective rubber manufacturing process that creates very little scrap product or waste. It is commonly used to manufacture long plastic profiles, such as complex door or window seals, along with rods, bars, and a variety of automotive applications.
Rubber Extrusion
Rubber extrusion uses the same method as plastic extrusion and is similarly cost-effective. Rubber extrusion allows companies to take advantage of the desirable properties of rubber—durability, flexibility, and resistance to chemicals, extreme temperatures, and abrasion, among others—in extruded products. This rubber manufacturing process allows for an incredible range of shapes, sizes, and levels of complexity. Rubber extruded parts are especially popular in the aerospace, automotive, construction, and marine industries.
Rubber Molding
Rubber molding is a common manufacturing technique for rubber products, compatible with everything from simple shapes to complex components. There are three primary methods of rubber molding:
Injection Molding
Injection molding is a highly precise rubber molding method, excellent for small, complex shapes, tight tolerances, and parts with internal features. The rubber injection molding process is very compatible with automation and high-volume production of rubber parts.
The rubber injection molding process is performed by injecting raw material inside a mold. The material is then cured, creating the desired shape.
Compression Molding
Compression molding is a manufacturing method well suited to simple shapes, such as o-rings, seals, and gaskets, and large components. Compression molding requires less machinery than other methods and has low tooling costs, making it a cost-effective option.
Compression molding is performed by placing unformed rubber into a mold. The mold is then pressurized and heated.
Transfer Molding
Transfer molding is a desirable rubber molding method for high cavity count molds and components that will undergo a secondary process. Transfer molding produces very little waste material.
Transfer molding is performed by plunging rubber through a series of small openings into a heated mold.
How UP&R Ensures Top-Quality Manufacturing
Universal Polymer & Rubber (UP&R) is proud to be a leading American manufacturer of rubber products. We are committed to providing our customers with the best possible experience, from the early stages of a new project to on-time delivery of their order. That’s why we have invested in multiple strategic measures, from coveted quality accreditations to consistent in-house collaboration, to ensure that we are always delivering the best products and services.
In-House Tooling, Design, and Manufacturing
We create all of our extrusion dies in house, allowing for close collaboration between the tooling team and the manufacturing team. For injection and compression molds, we collaborate with local, Northeast Ohio mold shops. As a result, we ensure consistent quality, faster turnaround times, and reliable delivery for our customers.
The entirety of our manufacturing operation is located on American soil. Our domestic supply chain is far less vulnerable to global disruptions, and we have constant oversight of every stage of production, so we can detect and address any potential issues right away and minimize any risk of delay.
Consistent APQP Efforts
Exceptional quality is the product of consistent work and strategic structure. Our team gathers on a weekly basis for advanced product and quality planning purposes. We are always working together to identify opportunities for improvement throughout the process of rubber manufacturing that will allow us to support our customers better.
Experienced Workforce
We have invested considerable resources over the years in recruiting, training, and developing true experts in the field of rubber manufacturing. Our team members have an average of twenty years of rubber manufacturing experience, bringing unparalleled expertise and informed perspective to every project.
ISO Certifications
ISO 9001 is a globally recognized standard for quality management systems and principles that supports continuous improvement, better performance, and an improved customer experience. The ISO 9001 accreditation process is rigorous, and certificates of approval are only granted to companies that match their high-quality standards.
UP&R is proud to have earned ISO 9001 accreditation at our facilities in Middlefield and Tallmadge, Ohio.
IATF Certifications
In addition to ISO 9001, our facilities in Tallmadge and Middlefield, Ohio, have also earned IATF 16949 accreditation.
IATF 16949 is a quality management standard specific to the automotive industry. IATF 16949 accreditation can support improved efficiency, faster deliveries, and greater customer satisfaction – all key priorities for UP&R.
Partner With UP&R For Exceptional Rubber Parts Manufacturing
If you’re looking for a rubber manufacturing partner you can trust, look no further than UP&R. Our highly experienced team members offer a level of expertise and commitment to quality that simply can’t be found anywhere else. From simple shapes to complex rubber components, we can deliver exactly what you need, on your timetable, so you can stay ahead of your competition.
Contact us learn more about our quality assurance practices or to discuss a project.