We have two main mold designs. The more common one is an “open mold” -- a process in which rubber is sandwiched between two (or more) matching open molds. Alternatively, using the “ejection mold” incorporates multiple layers of molds to manufacture products of more complicated design, such as those involving big undercuts. As the name suggests, the ejection mold facilitates the separation process.
It allows the intricate structures to be released from the molds
both quickly and without damage.
When it comes to interior design, every mold necessitates careful planning. Details such as determining the upper/lower parting lines, placement of air vents, and positioning of overflow grooves and cavities demand a scrupulous, methodical approach.
There are three general categories of molding processes:
Compression molding involves laying a material directly in the base mold then closing and compressing the molds using a press machine. After the rubber has filled the cavity and been cured, the molds are opened and the final product is taken out. This is the most commonly selected process by our clients due it being cost-effective, straightforward, and low in material waste.
While transfer molding resembles compression molding in its use of the pressing mechanism, the material is not manually applied into the cavity. Instead, it is placed in a pot where a plunger forces the rubber through a passage into the empty mold. Although transfer molding can cause bigger material loss and be more expensive due to its intricate mold layouts, this technique is ideal for products requiring high precision, uniform dimensions, smooth finish, and reduced parting lines.
Injection molding is unique because it involves a preset amount of rubber automatically being fed into the press machine. Though the most expensive, injection molding also has particular strengths that can make it the best choice. For example, injection molding is favoured for products requiring great delicacy, minimal exposure to contaminants, and rapid production in high volumes.
Each molding process has features that may make it more suitable for certain types of products but there is no set formula that dictates what is best. Rather, GEM carefully and extensively reviews all the options before making a decision. Just some of the many factors taken into consideration are: the clients’ preferred machine type, tolerance level in quality, production size, mold price, expected price of the product, and any elements particular to the product itself. Numerous trials are performed as we consult not only our expertise but also the client’s goals. Only then does GEM recommend the method that would best fit the client’s desired results.