Liquid silicone rubber (LSR) is a type of silicone elastomer liquid at room temperature and can be molded into various shapes using injection molding techniques. Its unique properties make LSR an essential material in the medical manufacturing industry. This ensures that medical devices and equipment are safe, effective, and durable.
This article will explore the uses of LSR in medical products and the manufacturing process behind it.
Applications of LSR in the Medical Manufacturing Industry
Below are some examples of how LSR is used in the manufacturing industry for medical products and equipment:
Medical Device Components
The flexibility, durability, and biocompatibility of LSR make it the preferred choice for most medical devices. These include catheters, syringes, and medical tubes and containers. It is also frequently used to seal respiratory masks and dental impressions for dental crowns and bridge works. Lastly, it is utilized to manufacture diagnostic equipment, including ultrasound gels and probe covers.
LSR is a popular material for implantable devices due to its high purity and resistance to heat and chemicals. It can also be molded into various shapes, allowing for the customization of implants to fit individual patient needs. Additionally, it is suitable for long-term implantation, making it ideal for artificial heart valves, breast implants, and cochlear implants.
Using LSR in surgical instruments gives surgeons the tools to perform complex procedures with greater precision and accuracy. Moreover, they can easily be sterilized using various methods, ensuring they are safe and free from harmful bacteria.
Wearable Medical Technology
Wearable medical technology has become increasingly popular, providing patients with real-time health monitoring and data collection capabilities. Examples of this technology include glucose monitoring systems, ECG monitors, and sleep trackers. The use of LSR improves patient outcomes and provides healthcare professionals with valuable data that can be used to optimize patient treatment.
Jefferson Rubber Works’ Certification and Capabilities
Jefferson Rubber Works, a leading supplier of custom rubber products, is pleased to announce that we have been awarded the ISO 13485:2016 certification for our Medical Device Quality Management System (QMS). It is an internationally recognized quality standard specific to the medical device industry that ensures the quality of medical device design, development, and production.
The certification underscores our commitment to providing high-quality rubber-molded products for the industry. In addition, our QMS focuses on delivering devices and related services that consistently meet customer and regulatory requirements. We also ensure our products are safe and meet customer needs through an audit, management review, and continuous improvement processes.
Manufacturing LSR components can often present unforeseen challenges that require creative problem-solving. At Jefferson Rubber Works, we have the expertise to meet these challenges head-on. With the addition of our Class 8 molding and component assembly cleanroom we are expanding our capabilities and strengthening our position in the market.
Partner With Jefferson Rubber Works for High-Quality Rubber Products and Services
With over 40 years of experience in the industry, Jefferson Rubber Works has become a leading supplier of custom rubber products and services! Our capabilities include liquid silicone molding, rubber injection molding, transfer molding, thermoplastic rubber, and composite moldings. We also specialize in meeting customers’ unique needs in various markets, including the medical industry.
Plastics have become the material of choice for manufacturers using injection molding processes. Generally, plastic has strong, lightweight, and easy-to-mold characteristics suitable for molding required parts and components. However, some plastics, like thermoplastic elastomers, cannot withstand extreme heat and are more prone to distortions when exposed to very high temperatures.
For this reason, manufacturers in a wide range of industries prefer rubber silicone to produce parts efficiently and economically. Liquid silicone rubber (LSR) is one great innovation for injection molding. The silicone’s basic structure is made up of duplicating Si-O chains (or polyatomic anions consisting of silicon and oxygen, also called silicate). LSR is highly flexible in nature, providing unique properties such as:
Wide temperature operating range
Good corrosion resistance
Long service life
Advantages Of Using LSR In Injection Molding
The following are some of the benefits of using liquid silicone rubber in silicone rubber injection molding:
Superior Heat Stability
LSRs can withstand temperatures as high as 180℃ without melting or trickling. Due to this, they are common for heavy-duty and automotive applications such as seals and gaskets. LSR is also the preferred material for other industrial applications because of its high thermal ability.
LSRs can withstand temperatures as low as -50°C. They are an excellent choice for any device that requires a low-temperature operation. This advantage is in contrast with most thermoplastics which become more rigid and brittle when exposed to low temperatures.
Aging resistance is critical when selecting a material for your injection molding procedure. LSR materials that have been cured are highly resistant to UV rays, weathering, and aging. They are ideal for applications that require extended outdoor exposure.
LSR has low water absorption and excellent resistance to common chemicals even when exposed to extreme temperatures as compared to most thermoplastics which only offer chemical resistance in moderate temperature ranges.
Low Compression Set
Low compression set materials can withstand structural damage under severe stress. LSRs have a low compression set, typically between 15% and 20%. They retain their elastic properties even when compressed for extended periods of time.
Great Shelf-Life Reliability
The shelf life of liquid silicone rubber is one of the key factors in determining its ease of use in a production line. The majority of LSR products have a shelf life of one year.
Manufacturers of electronic components must ensure that their materials can withstand corona discharge or voltage spikes. LSR has a high electrical stress resistance without affecting the final product’s conductivity.
Precision Made Molded Rubber Parts by Jefferson Rubber
Since the late 1970s, liquid silicone rubber injection molding has been used in various industries, including health care, medical, consumer goods, automotive, devices & electronics, and aerospace. Silicone rubber injection molding has been one of the most efficient and economical processes in molding rubber parts or components.
Jefferson Rubber Works, Inc. manufactures high-quality molded rubber parts and offers various rubber molding capabilities, including liquid silicone injection molding, rubber-to-metal molding, compression molding, transfer molding, and more! We provide a complete solution that includes part design, prototyping, production, finishing, and assembly, all at a quick turnaround time and cost-efficient rate.
With our 40 years of experience in the rubber manufacturing industry, we ensure to eliminate the need to work with multiple vendors. We can serve as your one-stop shop to meet all your custom rubber molding requirements and produce the high-quality products that you need.
Liquid silicone rubber injection molding, or LSR molding, is one of the most preferred methods for manufacturing precise and delicate components. This process is clean and highly accurate, produces high output, and offers superior strength and efficiency when integrated with the clean manufacturing technique of liquid injection molding.
This article will discuss the properties of LSR that make it suitable for liquid injection molding and the clean manufacturing process.
Characteristics of Liquid Silicone Rubber
Liquid silicone rubber is a high-purity platinum-cured silicone with physical, chemical, and thermal characteristics that make it ideal for products requiring excellent productivity, durability, and efficiency. In addition, LSR has the following properties:
LSR’s silicone-oxygen structure has a higher bond strength than polyethylene or carbon-based materials. It is also resistant to oxidation, UV rays, water, ozone, and radiation damage. Because of its inertness, LSR is an excellent choice for food contact, medical applications, and silicone prototyping.
LSR is naturally hypoallergenic and non-toxic and will not irritate or trigger allergic reactions in those with sensitive skin. Thus, it offers a safe and convenient remedy for respiratory products — such as oxygen and CPAP masks — and consumer items like earbuds, hearing aids, and portable monitoring devices worn for long periods.
The molecular structure of LSR also plays a role in its biocompatibility; it is odorless and tastes nothing. As a result, it is extensively used in baby products and other food and beverage-related goods because it adheres to the Food and Drug Administration (FDA) requirements.
The mechanical and thermal stability characteristics of LSR are exceptional, resulting in it being preferred over other elastomeric polymers. In addition, it retains its properties at wide temperature ranges — high and low — varying from -40 ℃ to 200 ℃, depending on the grade.
Clean Manufacturing Process
The most consistent and stable materials utilized in the liquid silicone rubber injection molding process are platinum-cured polymerics. The vulcanization or curing process employs a two-part silicone compound (composed of A and B parts in different containers) attached to the pumping system and delivered to a static mixer at a predetermined ratio. Compound A is usually the base-forming material, whereas Compound B is a catalyst.
The mixture is combined with a platinum cure system before being injected into the mixing chamber. Next, it is added into the closed mold via a runner and gate system. Once cured, the components are removed from the mold cavities, and the process is repeated for the next batch.
Following that, the products may be subjected to post-molding, which includes the following processes:
Deflashing: This method eliminates the residual rubber material used in injection molding. This is done via a centrifugal barrel finishing machine, a quick and cost-effective equipment to deflash multiple components.
Post curing: This process is subject to high temperatures to accelerate curing and optimize some of the material’s physical parameters. This will also speed up the cross-linking process and ensure that the polymer molecules are correctly aligned.
Inspecting: This process generates precise and prompt dimensional data and performance test results for molded parts.
Packaging: This is the final step in preparing the molded parts for shipping after a thorough inspection.
Only the Best and Highest-Quality Molded Parts From Jefferson Rubber Works
Jefferson Rubber Works produces high-quality molded rubber parts and provides a wide range of rubber molding services, including liquid silicone injection molding, rubber-to-metal molding, compression molding, transfer molding, and more. We also offer a complete solution with part design, prototyping, production, finishing, and assembly — all with a quick turnaround and low cost!
Water well pumps extract water from wells to supply residential, commercial, industrial, and agricultural applications. These are important components of well systems, so they need protection to avoid costly replacement and repair. Doing so can prevent excessive wear and tear on the well pump and avoid water supply interruption.
A diaphragm water pressure tank is a low-cost and effective way to safeguard your water well pump. Utilizing and maintaining the tank effectively will provide a consistent water supply and save you money in the long run.
This article provides a detailed guide on protecting your water well pump with a diaphragm water pressure tank.
Maximizing Well Pump Lifespan With a Diaphragm Water Pressure Tank
A diaphragm water pressure tank will prevent unnecessary damage to a well pump by letting it rest between cycles. However, properly installing, using, and maintaining the tank is still important to take advantage of its full benefits.
Here are four things to remember and follow when using a diaphragm water pressure tank for your well pump:
1. Correctly Install the Diaphragm Water Pressure Tank
The rubber diaphragm in the water pressure tank is a barrier between the pressurized air and water. Then, it allows the air to compress and expand as the water level in the well changes. Thus, installing the tank according to the manufacturer’s instructions is crucial. For instance, it should be connected to the pump with the correct pipe size and fittings.
2. Adequately Adjust Air Pressure
The air pressure in the tank is used to regulate the water pressure. It also prevents short cycling of the well pump, which can cause excessive wear and tear and shorten its lifespan. Therefore, you must adjust the air pressure to the correct levels to maintain and protect the well pump.
3. Regularly Check for Leaks
A diaphragm water pressure tank with leaks will not function as intended and might cause damage to the well pump. Therefore, regular upkeep and inspection are important to ensure its performance and condition. This will also help keep the air pressure in the tank at the proper level to strengthen the durability of the water well pump.
4. Maintain the Tank
Regular maintenance of the pressure tank helps to prevent the build-up of rust, corrosion, and sediment in the tank. This prolongs the life of the well and reduces the need for costly repairs. Neglected pressure tanks can also leak dirt, rust, and other contaminants into the water source and disrupt the supply.
Jefferson Rubber Works: A Reliable Supplier of Rubber Diaphragms for the Water Tank Industry
A rubber diaphragm in a water pressure tank can protect a well pump and improve its performance. By consulting with an expert in rubber diaphragm manufacturing, you can get a guaranteed high-quality product tailored to your specific needs.
Jefferson Rubber Works is a trusted manufacturer of custom rubber products! Aside from pressure tanks, our rubber diaphragms have applications ranging from actuators and flow control valves to switches and turbochargers.
Rubber injection molding is an efficient technique for manufacturing precise rubber parts and rubber-to-metal bonded components. It creates products with faster cycle times than transfer or compression molding. In addition, due to its advantageous qualities, it is widely used in various industries, such as the automotive, food and beverage, medical, electronic, and agricultural sectors.
The rubber injection molding process started in the mid-1960s after the successful modification of the plastics method. This procedure involves heating the rubber and exerting greater pressure per square inch on the cavity surface.
In this article, we will elaborate on the basics of the rubber injection molding process and how it works.
What Is Rubber Injection Molding?
The rubber injection molding process molds uncured rubber by injecting the raw material into a metal mold chamber. It provides precision and efficiency not typically observed in other rubber manufacturing processes. It is also suited for applications utilizing compounds with quicker curing durations.
Here are some of the common applications and uses of rubber injection molding:
What Are the Components of the Rubber Injection Molding Process?
Like any other methodologies, the procedure begins with material preparation. One advantage of rubber injection molding is that it allows the use of different varieties of rubbers.
The following are the most frequently utilized materials in the manufacturing industry:
Hydrogenated nitrile butadiene
In addition to the raw rubber material, an injection molding machine or press is required. Common components include an injection ram, a heating system, and a hopper. Also called platens, they support the molds used to shape the components.
Injection molding machines or presses are graded by their tonnage, indicating the amount of clamping force the machine can exert. Tonnage can range from less than 5 tons to more than 9,000 tons, with very few manufacturing operations employing the higher amounts.
How Does the Rubber Injection Molding Process Work?
Rubber injection molding starts with the bulk mixing of raw rubber, followed by its stripping into continuous lengths. Next, they are fed through a screw into a barrel containing a predetermined quantity of rubber material. The screw then preheats the material before being injected into the cavities. This reduces the substance’s viscosity, allowing it to flow freely into the cavities.
The rubber stock plasticizes to the desired temperature while heating. Then, the plasticized rubber material is injected into a heated, high-pressure mold chamber. Using a runner and a gate system, heat and pressure initiate the curing of the rubber compound, ultimately vulcanizing it. Once the required level of cure is achieved, the rubber is allowed to cool and harden in the mold. Lastly, the pieces are ejected from the mold in preparation for the next cycle.
Jefferson Rubber Works for High-Quality Rubber Injection Molding Solutions
At Jefferson Rubber Works, we combine industry experience with cutting-edge technology to provide customized solutions and services at affordable costs and unmatched speed and precision. We can also assist you with component design, prototype, manufacture, finishing, and assembly, so you do not need to collaborate with many companies for a single project.
Contact us today to find out more about our services and solutions. You can also request a quote, and we will be happy to assist you with your needs!
Jefferson Rubber Works Inc., a custom manufacturer of rubber molded products, has announced the will be completing a Class 8 Medical molding room for 2022. “The Class 8 Clean Room will allow us to expand in the manufacturing of custom rubber products for the medical industry,” said Company President Dave Pentland. “Our class 8 clean room is ideal for our customers with high volume medical devices or other products that require an ISO-certified hygienic production environment,” Pentland stated.
The company is currently ISO 9001-2015 certified, as is working on its ISO – 13485 Certification, also expected in later in 2022.
The primary focus of the Clean room will be LSR and TPR injection molding with addition equipment schedule later in the year.
“There is currently a big demand for molded medical devices and components – due to the Pandemic and new orders are coming in fast. Jefferson Rubber continues its efforts to be the leader in custom rubber molded products, providing exceptional quality and superior customer service,” Pentland said.
About Jefferson Rubber
Jefferson Rubber Works is a leading manufacturer of custom precision, injection molded rubber products. Jefferson Rubber’s staff brings a broad spectrum of expertise and insight to every job. The company offers complete in-plant engineering services, from prototype design to finished product. For more information call 508-791-3600 or visit the Jefferson Rubber Works website: www.jeffersonrubber.com.
Modern business practices include a continuous review of all the processes and procedures employed in the business to ensure that it remains competitive and that the business model is sustainable. This forms the basis for internationally recognized standards such as the ISO 9001:2015. This standard is used by companies to ensure that their business consistently provides products and services that meet customer and regulatory requirements and follow a process of continuous improvement.
What is cost efficiency?
Cost efficiency is often defined as the act of saving money by making a product or performing an activity in a better way.
What factors drive up costs?
Raw material costs
Over delivery of services or over-specification of products
Poor employee performance and staffing levels
Incorrect or irrelevant standards
How do you identify inefficiencies?
A thorough analysis of processes in business relies on valid, accurate, and current data. Without these, a baseline cannot be established, and it will not possible to measure any improvement that changes to business practices or procedures will make.
This is a thorough investigation of the current status of the business as a whole or even parts of a company such as a production line or a specific service. It involves looking at all processes procedures and costs, documenting and then analyzing them.
A gap analysis compares actual performance or results with what was expected or desired. This calls for the identification of best practices employed by competitors or other players in a similar business, either locally or globally. Suboptimal or missing strategies, structures, capabilities, processes, methods, technologies or skills can then be identified.
Once the GAP analysis has been concluded, recommendations can then be made that will assist the company to meet its goals in maximizing profits and delivering quality products to the market.
Jefferson Rubber Works is an ISO9001:2015 accredited company and has had an ISO certification for several years as part of its dedication to manufacturing quality and defect-free products. Quality management is a cornerstone of their business model with a strong commitment to the process from all staff.
Jefferson Rubber Works subscription to ISO9001:2015 principles has provided additional benefits to the company by reducing wastage, improving productivity, while customers benefit from lower product prices and consistently high-quality products. The standard assists the company across many levels, including customer focus, improving management and processes within the company. Adherence to these standards results in a process of continual improvement in the quality of products and services while reducing wastage of resources. Learn more about our USA rubber molding supplier capabilities here.
Customer service is the main reason consumers choose small businesses over their larger competitors. Their top requirements are for personalized interactions and the supplier’s extensive knowledge of customers’ needs. Today’s business conditions often require suppliers to be agile and able to respond to changes in the market at short notice. This is where small businesses come into their own and why we at Jefferson strive to always keep the customer front and center.
Why work with a small company?
#1 – Culture
Smaller companies are likely to be run by management and staff who have taken the company from a start-up business to become a reputable supplier. During this process, the company will have developed a corporate culture that its employees fully understand and subscribe to. Corporate culture forms a big part of the brand that customers identify and will want to work with.
#2 – Customer Relationships
The customer is the reason for the business. Smaller businesses and their customer-facing staff are more sensitive to this fact than their larger competitors. Customers are more likely to be dealing with the same person regularly when dealing with a smaller company and, in the process, develop closer inter-personal relationships. The person responding to the customer call in a small business is also likely to be an owner or someone who has a deep understanding of the company, its products and be a decision-maker, This makes them able to attend to a customer’s requirements immediately.
#3 – Flexibility
Small companies are inherently more flexible than their larger competitors. The decision-making process is shorter and often only involves a single person. They are, therefore, able to react quickly to any change in customer requirements or any potential problem arising from an order. These businesses have also learned that their survival depends on being able to respond rapidly to changing market conditions or lapses by competitors.
#4 – Specialization
Smaller businesses tend to focus on niche markets where either their specialized knowledge or unique products set them apart from their competitors. By specializing, a small business can often charge a premium for their products and improve margins. Being a specialist in a specific field and delivering a quality product are essential factors in ensuring the sustainability of a small enterprise.
#5 – Communication
Well run smaller businesses place a significant emphasis on internal and external communications. They focus on regular communication and feedback to their clients while at the same time keeping their staff well informed of the latest developments and changes in customer requirements. They also stay abreast of the latest technology and communication aids and incorporate their customer’s needs into these systems.
#6 – Employee Engagement
Staff in smaller companies tend to have a closer relationship with their employer than might be the case in a larger business. Although opportunities for advancement may not be as readily available as in more prominent companies, levels of commitment to quality and meeting production targets are often very high. They are also open to cross-skilling which adds to employee satisfaction levels and ultimately to a better understanding of customer needs.
Jefferson Rubber Works is a leading supplier of custom rubber products based in the United States of America. Their highly skilled staff and a company with more than 40 years of experience can meet every custom rubber molded injection requirement. They will give you a fuss-free “one-stop shop” experience from concept and design to the final high-quality product you need.
Understanding different tariffs and duties in important for US businesses as it helps to give context to buying locally made products that don’t have the same high taxation rates. Tariffs or duties are taxes imposed on imports or exports between countries. The primary aim of an import tariff is to regulate foreign trade. Import tariffs are a part of a government’s policy that taxes foreign products to encourage or protect domestic industries and businesses. They serve as a source of income for governments, much the same as various other forms of consumption taxes.
The tariffs that the government of the United States of America are applying to imported goods and services from countries across the globe are intended to support local American industries and increase employment opportunities.
Protecting domestic employment – Political parties often raise the possibility of increased competition from imported goods that can threaten domestic industries to mobilize an electorate;
Protecting consumers – In some instance’s tariffs may be imposed to protect local consumers from sub-standard or hazardous products;
Infant industries – Governments, particularly in developing countries, may impose tariffs to shield infant and start-up industries from the external competition;
National security – Tariff barriers may be employed by governments to protect strategic economic sectors such as defence contractors or providers of information and communications technology;
Retaliation – Countries can set tariffs as retaliation for a perceived or real subversion of trading rules or solely for political purposes.
Who pays for the import tariffs or duties?
Ultimately domestic consumers in the importing country pay for the tariffs levied by their government on specific categories of imported goods or services. The tariffs are not levied at the source of the import so they do not directly affect the exporting country. The net effect is, however, to make foreign products more expensive for consumers and may ultimately lead to reduced demand for such products or import substitution. If manufacturers rely on imported components or other inputs in their production process that are subject to import tariffs, they will either have to pass on the increased cost to consumers or absorb this cost while reducing their profit margin.
Types of tariffs and duties
Specific tariffs – the duty is calculated at fixed amount per unit that is imported;
Ad valorem tariffs – the tariff payable is based on a percentage of the value of the goods;
Licenses – importers must obtain costly licenses to import certain products. The cost of these licenses is passed on to the consumer, pushing up the cost and reducing demand. This ultimately leads to a reduction in business competitiveness;
Import quotas – quotas are set to limit the imported volumes of certain targeted items;
Voluntary export restraints – these are export limitations imposed by exporting countries in response to similar restraints set by trading partners to protect certain industries or sectors in each other’s countries;
Local content requirements – local content requirements are introduced to support to ensure that a portion of inputs for local production are locally sourced and not imported.
Jefferson Rubber Works is an American owned and based company, primarily supplying customers within the United States of America. Our history of supplying high-quality rubber molded products stretches over more than 40 years. We’re proud that over 85% of our comprehensive range of products are manufactured locally in our modern production facility in Worcester, Massachusetts.