Elastomer Prototyping: Ultimate Guide
Elastomers of different types are used in manufacturing a wide range of components. Sometimes, they are also used for making prototypes.
If you are looking forward to learning about elastomer prototyping, the guide below is the key to the details.
What is Elastomer?
Elastomers are polymers which offer elasticity and viscosity.
Elastomer molecules can be joined together with the help of weak intermolecular forces that offer high yield strength and low Young's modulus.
Elastomers have the ability to gain their actual shape again after they have been stretched.
Types of Elastomer
There are two types of elastomers, and each type has its properties, as discussed below.
Saturated Elastomer
Saturated elastomers offer stability against ozone, radiation, heat and oxygen. These are not curable by sulfur vulcanization and have less reactivity.
Silicone and polyacrylic rubbers are the types of saturated elastomers.
Unsaturated Elastomer
Unsaturated elastomers are capable of being cured with the process of sulfur vulcanisation. The types of unsaturated elastomers are composed of natural polyisoprene and butyl rubber.
Methods to Produce Elastomeric Prototypes
There are different methods which can be used to produce elastomer prototypes, and these are as follows:
CNC Milling
CNC milling is a process in which the software instructs tools of a CNC machine to shape and cut the elastomers.
The nature of elastomers is highly flexible, and this requires a lot of care during the machining process.
It is very important to avoid deformation by choosing the right speed of cutting tools and cooling methods.
The process of CNC milling is suitable for such prototypes of elastomers that need high accuracy, complex geometries, and intricate details.
It is usually opted for low-volume production of elastomer components.
Injection Molding
Injection molding also helps manufacture elastomer prototypes in larger quantities. The elastomers are melted and injected into the mold, which has already been manufactured beforehand.
Once the molten elastomer has cooled down and solidified, it is demolded.
The process of injection molding can be repeated multiple times to manufacture more components of the same design.
It is very easy to manufacture prototypes of different elastomers using injection molding. The cost of mold, however, is high, and hence it is suitable for high volume production.
3D Printing
3D printing deposits the material layer by layer to create a 3D component. Elastomer materials can also be used for manufacturing properties using 3D printing.
The process is flexible and offers quick changes with no expenses whenever needed in the design. Hence, this process is suitable for short runs and rapid prototyping.
It helps to create complex components and that too very quickly.
Design Considerations Of Elastomer Prototyping
When carrying out elastomer prototyping, there are a few design considerations that play a vital role, and these are as follows:
Material
When designing the prototype of elastomers, the right type of elastomer should be chosen for the application. The hardness, flexibility, strength and elongation are the aspects to consider.
Moreover, the compression ability of the material should be assessed to ensure it retains its original shape over time.
Wall Thickness
The thickness of the wall when manufacturing a prototype using an elastomer is important to maintain. When doing processes like injection molding, inconsistent thickness may lead to warping.
Hence, the thickness of the walls must be accurate. The thin walls lead to deformation and thick lead to improper filling.
Complex Shapes
If the design has complex geometries, the elastomer prototyping can be challenging. It could lead to difficulty in ejecting the component and deformation.
In this case, the use of flexible inserts, draft angles and multi-part molds can be helpful.
Consider Shrinkage
Elastomers have a tendency to shrink once cured or molded. Hence, when designing a prototype using elastomers, consider the shrinkage.
Moreover, sometimes it gets very difficult to maintain tolerance with elastomers due to high flexibility; hence, setting realistic expectations is important.
Surface Finish
The surface finish of the elastomers plays a vital role in aesthetics as well as functionality.
Hence, it is important to have a smooth finish to help reduce friction. At the same time, a textured surface helps enhance grip.
The finishing of the prototypes also impacts the way elastomers interact with coatings. Hence, a finish should be chosen with the balance of performance and appearance in mind.
Start Prototyping Rubber Parts Efficiently with DEK
DEK offers to manufacture prototypes of rubber parts using different manufacturing processes.
We analyze the type of elastomers you want to use and choose the most relevant manufacturing process.
We have a team of expert engineers to offer their expertise in the manufacturing process of your components. So, get in touch with us to make the best of our prototyping services.
Conclusion
Understanding details about elastomers, processes involved in prototyping them, and their types is very crucial before you use them in your projects.
As you have read the guide above, every detail regarding the material must be clear allowing you to make informed decisions.
