Micro rubber parts
The miniaturisation of parts and equipment in the automotive, instrumentation & electronics and medical markets particularly, is driving the need for micro rubber moulding of ever smaller components. But ultra-small, flash free parts are incredibly difficult to produce.
However, sub-millimetre detailing is nothing new to DP Seals. In fact, it is one of the key things that sets us apart as a manufacturer in the rubber seals, gaskets and mouldings market.
As far back as 1979 we produced a miniature O Ring with an internal diameter of just 0.05mm, setting new standards in the industry at the time.
Micro detailing on larger parts
Of course micro moulding isn’t just for small parts. It can also apply to incorporating micro detailing on larger parts, such as thin wall structures, tiny holes, or other complex features.
Rubber to metal bonding
Often the requirement for micro moulding can be combined with the need for inserts and rubber to metal bonding, such as in instrumentation and electronics and semi-conductors. As specialists in this area DP Seals are well placed to help you with your application.
Getting the best results
To get the best results for your micro moulding project it is important to choose a manufacturer with a combination of technical expertise and experience, material selection, in-house tooling, manufacturing, quality control and project management.
Choosing such a manufacturer ensures that any problems can be ironed out and changes implemented quickly and effectively to ensure the fastest speed to market. Let’s look at the importance of these in a little more detail.
Technical input
With over 40 years experience we can help with your most difficult challenges and have partnered with engineers from a wide variety of industries across the globe to find solutions to meet the most exacting requirements.
Material selection
Micro moulded parts often require custom compounds and materials which must be treated delicately to ensure the highest levels of quality throughout the process.
The most common polymers used are often silicone grades but DP Seals works closely with compounders, testing and analysis companies to ensure you get exactly the right blend for your application. This is so important as material selection plays a key part in tolerance, dimension, feature development, functionality and, of course, cost.
Micro Rubber Tooling
Our tool room has all the latest rubber mould tool technology, and this ability to produce ultra precise tooling in-house means you’ll get the high accuracy features you require with a shorter and stronger manufacturing process.
Some of the components we have been asked to manufacture are so small that suitable off the shelf tools just didn’t exist. In these cases our tool room engineers have made their own.
Transfer and Compression Moulding
At DP Seals we typically use transfer moulding for micro parts as it is a far better method compared to injection or compression alternatives. It is a technique where very low pressure and gentle “hands on” processing is required. This enables incredibly tight tolerance holding and very fine, almost imperceptible, moulding split lines.
Quality control
We operate the rigorous AS 9100 Quality Management System and were one of the first companies in the UK to achieve ISO 9001 certification.
With our patented moulding system we can virtually eliminate flash altogether. Of course, in the few cases where it might be required and appropriate, we also have fluorination and cryogenic cleaning services to ensure parts meet the highest levels of quality.
Finally, parts are packaged and labeled in accordance with customer specifications and to ensure batch and process traceability.
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As someone who has been assessing suppliers for over 20 years it was quite apparent to me that DP Seals are technical experts and industry specialists. In meeting our 4M and QCDES standards it was their personal touch and attention to detail that helped set them apart. Natasha Witcombe Technical Procurement Engineer, Ricoh
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