Choosing the right manufacturing method for custom rubbers parts can be challenging. There are many options to choose from, each offering its own unique set of advantages and limitations. The purpose of this article is to break down the differences between two popular methods—rubber extrusion and rubber die cutting—with the goal of creating a stronger understanding of their benefits and best applications.
What Are Custom Rubber Parts?
Custom rubber parts are rubber components uniquely designed for a specific purpose or application. The flexibility of rubber as a material means that rubber parts are almost infinitely customizable. Of course, parameters such as size, shape, and color can be modified to meet a wide range of needs, but other variables, such as manufacturing techniques, finishes, and material composition, can also be adjusted to fulfill specific criteria. Whether the final customer wants a precise look, a specific set of performance attributes, or a final product that comes in under a tight budget, custom rubber parts can undoubtedly be made to meet their needs.
One example to explore is manufacturing technique; specifically, the difference between rubber extrusion and rubber die cutting when making custom rubber parts.
Understanding Rubber Extrusion
What is Rubber Extrusion?
Rubber extrusion is a rubber manufacturing process optimized for creating precise two-dimensional shapes, cut to a variety of lengths. A prepared rubber compound is forced through a custom die, creating a continuous length. The process occurs in a controlled environment to ensure that the extruded shape remains consistent as it sets. The extruded shape is later cut into precise lengths based on its intended applications. This can range from short sections to long pieces that can wrap around a door, window, or panel.
Benefits of Extruded Rubber
Rubber extrusion offers a few key benefits. Extruded rubber parts are highly customizable, and the design process is extremely flexible, creating opportunity for a wide range of shapes. Extruded rubber shapes can be cut to virtually any length. Plus, the rubber extrusion process itself is fast, cost effective, and produces minimal waste when compared to other rubber manufacturing processes.
When to Use Rubber Extrusion
Rubber extrusion is an excellent manufacturing choice for applications that require consistency across considerable length. Examples include long, uniform components, such as seals, gaskets, trims, tubing, and weatherstripping. Additionally, extruded parts can be quite durable, making rubber extrusion a reliable choice for components destined for intense service environments.
Understanding Rubber Die Cutting
What is Die Cut Rubber?
Die cut rubber is rubber cut from a sheet into a precise shape with a specialized die. The process usually uses a hydraulic press or a rotating cylinder to apply pressure to the die so it can stamp through the rubber sheeting and create the desired shape. The process is somewhat analogous to using a cookie cutter to cut shapes from rolled-out dough.
Benefits of Die Cut Rubber
Rubber die cutting is a highly efficient method for cutting a high volume of identical shapes, with consistent cuts and good edge quality. While there is some upfront cost associated with creating the die itself, dies can be used over and over. So once the die is created, the process is very cost effective.
When to Use Rubber Die Cutting
Die cutting is an excellent choice for high-volume orders of flat, simple components, such as gaskets or washers. Because the up-front tooling costs of creating a new die can be high, die cutting may not be the best option for projects that require regular design changes. Additionally, manufacturers seeking complex shapes may want to consider alternatives, since rubber die cutting is best suited to simplicity.
Rubber Extrusion Rubber Die Cutting
| Best Applications | Two-dimensional components in a variety of cut lengths | Flat components with simple shapes |
| Volume Efficiency | Best for longer components | Excellent for high volumes |
| Design Flexibility | Offers considerable design flexibility | Best for simple shapes |
Choosing the Right Approach for Your Custom Rubber Parts
Whether you’re evaluating your options or ready to get started with a custom rubber parts manufacturing project, UP&R has got you covered.
As an experienced custom rubber parts manufacturer, we can help you choose the best materials and manufacturing method for your part. You can count on our experts to consider your budget, your product’s service environment, and other factors when evaluating your options with you.
Our facilities in Northeast Ohio are equipped for efficient rubber extrusion and rubber die cutting, so you can get your work done entirely on American soil. We also do our own tooling in house, so we have greater control over the quality assurance process and can guarantee precision on every project.
Ready to get your custom rubber parts started? Get a quote.