High Elasticity LSR Liquid Silicone Rubber Custom Molded Industrial Parts

# High Elasticity LSR Liquid Silicone Rubber Custom Molded Industrial Parts

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Product Overview

Our High Elasticity LSR Liquid Silicone Rubber Custom Molded Industrial Parts are precision-engineered components manufactured via injection molding of medical-grade, food-grade, and industrial-grade two-part liquid silicone rubber compounds, tailored to meet the exact performance demands of harsh operating environments. Unlike traditional solid silicone, thermoplastic elastomers (TPE), or rubber materials, these LSR parts combine exceptional elastic recovery, extreme temperature resistance, and long-term durability to address common industrial pain points such as material fatigue, seal failure, and degradation when exposed to chemicals or UV radiation.

Core selling points of the product include 100% customizability for geometry, hardness, and material formulation, >90% tensile elongation at break for high-strain applications, consistent dimensional precision within ±0.02mm tolerance for complex assemblies, and compliance with global regulatory standards for medical, food contact, and automotive use cases. All parts are produced in a closed-loop injection molding environment to eliminate contamination risks and ensure batch-to-batch consistency for high-volume production runs.

Technical Specifications

Material Properties

All parts are formulated with platinum-catalyzed addition-cure LSR, free of peroxides, phthalates, and volatile organic compounds (VOCs) to meet strict safety requirements. Key material properties include:

Physical Performance

The high-elasticity formulation ensures parts maintain structural and functional integrity across extreme operating conditions:

• Continuous operating temperature range: -60°C to 220°C (up to 250°C for short-duration exposure; high-temperature grade supports 300°C continuous use)
• Thermal conductivity: 0.2–0.3 W/(m·K) (thermally conductive grade available up to 3.0 W/(m·K) for heat dissipation applications)
• Dielectric strength: 20–25 kV/mm, volume resistivity >10¹⁴ Ω·cm for electrical insulation use cases
• UV and ozone resistance: Zero degradation after 1000 hours of accelerated QUV exposure (340nm, 0.89W/m²)
• Chemical resistance: Compatible with dilute acids and bases, neutral salt solutions, engine oils, and hydraulic fluids; fluorinated LSR grades offer enhanced resistance to aliphatic hydrocarbons and alcohols.

Process Parameters

All parts are produced via high-precision liquid silicone injection molding with the following standard process controls to ensure consistency:

• Molding temperature range: 130–180°C (platen temperature differential controlled within ±2°C)
• Injection pressure: 50–150 bar, adjusted based on part complexity and wall thickness
• Cure time: 10–60 seconds per mm of wall thickness, with post-cure (1–2 hours @ 200°C) optional for low-extractable applications
• Dimensional tolerance: ±0.02mm for parts with dimensions <50mm; ±0.05mm for dimensions between 50–200mm, compliant with ISO 3302-1 Class M2 precision standards
• Flash control: <0.05mm for all sealing and assembly surfaces, with automated deflashing available for high-volume orders.

Product Advantages

1. Unmatched Elastic Recovery for Long Service Life

The high-elasticity LSR formulation delivers >98% shape recovery after 10,000 cycles of 50% compressive strain, outperforming TPE (85% recovery) and EPDM rubber (78% recovery) in cyclic loading applications. This eliminates permanent deformation, a common cause of seal failure, gasket leakage, and cushioning performance loss, extending part service life by 3–5 times compared to conventional elastomer parts. For dynamic sealing applications, this translates to fewer maintenance shutdowns and lower total cost of ownership.

2. Customizable Formulations for Targeted Performance

Unlike off-the-shelf silicone parts, we offer full customization of material properties to match application requirements: flame-retardant grades meet UL94 V-0 standards for electrical and electronics use, self-lubricating LSR grades reduce friction coefficient by 40% for moving assembly parts, and antimicrobial LSR grades with 99.9% bacterial inhibition rate are available for medical and food processing applications. No minimum hardness or formulation adjustment fees apply for production runs of 10,000 units or higher.

3. High Precision for Complex Assembly Integration

Our closed-loop LSR injection molding process supports complex geometries including undercuts, micro-sized features (as small as 0.1mm diameter holes and 0.05mm thick walls), and overmolding onto metal, plastic, or glass substrates without the need for adhesive. This eliminates assembly gaps and reduces part count for integrated components, making the parts ideal for precision assemblies in automotive sensors, medical devices, and consumer electronics.

4. Low Long-Term Maintenance Requirements

LSR parts are inherently resistant to hydrolysis, UV radiation, ozone, and most industrial chemicals, requiring no surface treatments or regular lubrication to maintain performance. Unlike natural rubber or nitrile parts, they do not crack, discolor, or become brittle after long-term outdoor or high-temperature exposure, reducing maintenance frequency and replacement costs for industrial equipment.

Applications

Our high-elasticity LSR custom molded parts are deployed across a wide range of industrial sectors, with common use cases including:

• Automotive Industry: Dynamic seals for electric vehicle (EV) battery packs, sensor diaphragms, charging port gaskets, and vibration dampers for advanced driver-assistance systems (ADAS) components. The material’s temperature stability and resistance to automotive fluids make it suitable for under-hood and exterior applications with 10+ year service life requirements.
• Medical Device Manufacturing: Implantable short-term catheter balloons, surgical instrument grip handles, sealing gaskets for diagnostic equipment, and biocompatible fluid transfer components. All medical-grade parts comply with ISO 10993-5 (cytotoxicity) and ISO 10993-10 (skin irritation) standards, and are produced in ISO Class 8 cleanroom environments upon request.
• Food and Beverage Processing: Gaskets for filling machine nozzles, conveyor belt bumpers, sealing components for commercial cooking equipment, and baby product parts such as bottle nipples and pacifier shields. Food-grade formulations meet FDA 21 CFR Part 177.2600 and EU 10/2011 food contact regulations, and can withstand repeated CIP (clean-in-place) and SIP (sterilize-in-place) cycles without degradation.
• Electrical and Electronics Industry: Waterproof sealing gaskets for consumer electronics, thermal interface pads for 5G base station components, high-voltage insulation parts for power distribution equipment, and keypad buttons for industrial control panels. Flame-retardant grades meet UL94 V-0 requirements for fire safety in enclosed electronic assemblies.
• Industrial Equipment: Hydraulic and pneumatic system seals, valve diaphragms, vibration isolators for heavy machinery, and custom gaskets for chemical processing equipment. The material’s chemical resistance and elastic recovery reduce unplanned downtime caused by seal failure in harsh production environments.

Selection Guide

Hardness Selection

Choose Shore A hardness based on the functional requirements of your part:

• 20–30 Shore A: Ideal for soft sealing applications, cushioning pads, and parts requiring high conformability to uneven surfaces (e.g., IP67 waterproof gaskets for handheld electronics).
• 40–50 Shore A: The most versatile range, suitable for dynamic seals, diaphragms, and general-purpose gaskets that balance flexibility and structural stability.
• 60–80 Shore A: Recommended for load-bearing components, vibration dampers for heavy machinery, and parts requiring high wear resistance (e.g., conveyor system rollers).

Size Specifications

We support custom part dimensions ranging from 2mm micro-components (e.g., micro-seals for medical catheters) to 500mm large-format gaskets for industrial equipment. When submitting a design, provide 3D STEP files or 2D engineering drawings with tolerance requirements, and our engineering team will conduct a DFM (design for manufacturing) review to optimize part geometry for LSR molding, including recommendations for draft angles (minimum 1° for vertical surfaces) and wall thickness (0.5–10mm recommended to avoid molding defects).

Material Grade

Select the appropriate material grade based on your application’s regulatory and performance requirements:

• Industrial Grade: Cost-effective option for non-critical applications such as general seals, vibration dampers, and outdoor equipment components, with no food or medical contact requirements.
• Food Grade: Compliant with FDA and EU food contact regulations, suitable for food processing equipment, kitchen appliances, and consumer food contact products.
• Medical Grade: Low-extractable, biocompatible formulation for medical device components, with optional cleanroom production and full biocompatibility test reports available upon request.
• Specialized Grades: Including flame-retardant (UL94 V-0), thermally conductive, self-lubricating, and fluorinated LSR for high chemical resistance, available for custom formulation requests.

Quality Assurance

All high-elasticity LSR molded parts are produced under an ISO 9001:2015 certified quality management system, with strict inspection protocols at every stage of production:

1. Incoming material inspection: Each batch of LSR raw material is tested for hardness, tensile strength, and curing properties before being released to production, with material traceability records maintained for a minimum of 5 years.
2. In-process inspection: First-piece validation is conducted for every production run, with dimensional checks using coordinate measuring machines (CMM) and optical projectors to ensure compliance with drawing specifications. Process parameters are monitored in real time to avoid batch-to-batch variation.
3. Final inspection: 100% visual inspection is conducted for surface defects, flash, and dimensional conformity, with AQL 0.65 sampling for functional testing (including compression set, elasticity recovery, and pressure leakage testing for sealing parts) before shipment.

We offer a 12-month warranty against manufacturing defects for all parts, and can provide third-party test reports including material composition, biocompatibility, food contact compliance, and flame resistance upon request. For custom development projects, our engineering team provides 48-hour DFM feedback and 7–15 day rapid prototyping services to validate part performance before full production.