After confirming the excellent temperature resistance, sealing, flame retardancy and environmental friendliness of the silicone foam material, the next question for many engineers is: "How do we turn it into the desired final part?" Yes, the best material needs to be processed properly to get the most out of it.
As a professional supplier of silicone foam materials, we understand that "materials are the foundation, and processing is the realization". This article will give you a comprehensive understanding of several common processing methods of silicone foam materials, helping you to choose the best production process for your project.
Relationship between core characteristics and processing
Before discussing the specific processing methods, we must understand the two core forms of silicone foam materials, which directly determine the processing path:
1.Sheet/roll: a standardized thickness and width of material produced by calendering or extrusion processes, which is the basis for secondary processing.
2.Molded profile: a continuous strip of a specific section is formed directly by a mold, often used for sealing strips.
Based on the above form, we mainly carry out precision machining through the following "subtraction" or "combination" processes.
1. Die-cutting
This is the most widely used and economical processing method, especially suitable for sheets.
The principle: using a pre-made knife mold, the material is stamped into a specific two-dimensional shape under the action of the press, similar to a "cookie mold".
key technology ：
Tool selection: Based on material thickness and precision requirements, you can choose etching tool (high precision, complex shape), carving tool (durable, suitable for simple shape) or QDC tool (quick change tool).
Dirt removal: For back glue products or precision small parts, it is necessary to use waste needle or tear film plate and other technologies to ensure smooth waste removal.
Advantages: high efficiency, low cost, suitable for mass production.
Applicable products: sealing gasket, battery insulation sheet, electronic equipment internal buffer pad, conductive foam padding, etc.
2. CNC Machining
When die-cutting cannot meet the needs, carving is an ideal solution.
(Picture：These are CNC equipments of Sanpu Silicone Co.,Ltd)
Principle: Using precision CNC machine tool, the material is cut in three dimensions by high speed rotating milling cutter.
applicable scene ：
Small batch sample and prototype production: no mold opening, fast design verification.
Materials with very high thickness: ultra-thick sheets that can be processed far beyond the die-cutting capacity.
Complex structure: can make parts with steps, slopes, grooves and other three-dimensional structures.
Advantages: high flexibility, no mold, high precision.
Disadvantages: higher unit cost, lower production efficiency than die-cutting.
Applicable products: special equipment sealing ring, irregular shock absorption pad, medical equipment components, research and development stage samples.
3. Forming
It can be understood as a "die-cut" that is more suitable for specific occasions.
Principle: Use standard punch press and punch to stamp the material.
The difference with die-cutting: it is more suitable for parts with simple shapes (such as round or square), and usually single-cavity or few-cavity molds. The mold making is relatively simple and fast.
Advantages: For simple shapes, the mold cost is lower and the adjustment is flexible.
Applicable products: ordinary gasket, simple cushion, etc.
4. COMPOUND
The combination of silica gel foam material with other functional materials can achieve the effect of "1+1> 2".
Principle: The silicone foam is bonded to PET film, metal foil, non-woven fabric, other foam cotton or double-sided adhesive by heat pressing or adhesive bonding.
purpose ：
Enhanced features: Composite aluminum foil provides electromagnetic shielding, while composite PET film prevents adhesion.
Easy installation: Composite pressure-sensitive adhesive (back adhesive) enables instant peeling and sticking, simplifying the assembly process.
Enhance strength: composite fabric or film to improve the tensile strength and durability of the material.
Applicable products: sealing strip with installation patch, electromagnetic shielding gasket, fireproof composite roll material, etc.
So,How to choose the processing method?
If you need to produce large quantities of 2D flat products ,our priority is to use die-cutting.
If you need some samples,especially complex 3D, and thick materials, we perfer to prioritize engraving.
If you need to direct paste, select the back adhesive lamination process.
Still not sure how to choose? The best way is to talk to your material supplier.
As your trusted silicone foam material partner, we not only provide high-quality raw materials but also offer full precision processing capabilities from composite, die-cutting to engraving. We deliver one-stop solutions from material selection and process recommendations to finished product delivery, tailored to your drawings or requirements.
Contact our technical team now for free processing consultation and sample service! We will integrate the outstanding performance of silicone foam material into your product design with professional processing technology.
Call +86 18759819189 (Ula wang)