Silicone replica

Silicone replica, also known as vacuum replica, is a fast and cost-effective alternative solution for producing small batch injection molded parts. Typically, 3D printed SLA parts are used as prototypes, while molds are made of silicone material, and polyurethane PU material is poured through a vacuum injection process to create a replica.

The advantages of silicone replication

Silicone has excellent physical and chemical properties, making it a soft, transparent, high-temperature resistant, and chemically corrosion-resistant material. Silicone replica can provide protection in the following aspects:

Dust and Waterproof: Silicone molds can effectively block dust and moisture from entering the surface of objects, protecting their internal components from contamination and damage.

Anti scratch: Silicone molds have a certain degree of elasticity and softness, which can absorb external impacts and friction, reduce scratches and wear on the surface of objects.

Insulation protection: Silicone has good electrical insulation performance, which can to some extent isolate the surface of objects from external current and static electricity, prevent static damage and electric shock hazards.

Anti oxidation: Silicone molds can prevent oxygen and other oxidants from coming into contact with the surface of objects, slow down the occurrence of oxidation reactions, and extend the service life of objects.

Step 1: Create a prototype

The quality of the replica depends on the quality of the prototype. We can spray textures or perform other processing effects on the surface of the SLA prototype to simulate the final details of the product. Silicone molds accurately replicate the details and textures of the prototype, ensuring a high degree of consistency between the surface of the replica and the prototype.

Step 2: Create a silicone mold

The pouring mold is made of liquid silicone, also known as RTV mold. Silicone rubber has excellent chemical stability, self release performance, and flexibility, which can minimize shrinkage and effectively replicate part details from the prototype to the mold. The production steps of silicone molds are as follows:

Stick adhesive tape around the flat area of the prototype for easy mold opening in the future, which will also become the parting surface of the final mold.

Hang the prototype in a box and place a rubber rod on the part to set the pouring port and exhaust hole.

Inject silicone gel into the box and vacuum it, then cure it in an oven at a temperature of 40 ℃ for 8-16 hours, depending on the volume of the mold.

After the silicone is cured, the box and the adhesive rod are removed, and the prototype is taken out from the silicone to form a cavity. The silicone mold is then made.

Step 3: Vacuum injection molding

Firstly, place the silicone mold in the oven and preheat it to 60-70 ℃.

Choosing the appropriate release agent and using it correctly before mold closing is crucial to avoid sticking and surface defects.

Prepare polyurethane resin, preheat it to about 40 ° C before use, mix the two-component resin in the correct proportion, and then stir thoroughly under vacuum and degas for 50-60 seconds.

Pour the resin into the mold inside the vacuum chamber, and then cure the mold again in the oven. The average curing time is about 1 hour.

After curing, remove the casting from the silicone mold.

By repeating this step, more complex modules can be obtained.

Silicone replica has the following advantages:

(1) Low production cost. The processing cost is also much lower than CNC machining and 3D printing;

(2) Short production cycle. Save time on mold opening and greatly improve production efficiency;

(3) No need for mold opening. Save time on mold development, earn valuable time for customers to develop new products, and seize market opportunities;

(4) High degree of restoration, low probability of processing failure;

(5) Suitable for small batch production, with short customization time and low cost;

(6) Exquisite and meticulous workmanship, without burrs.

Silicone replica, choose industrial professionals for more professionalism and peace of mind! The service life of industrial molds is 20-25 at a time, equipped with advanced German equipment. The precision dimensional tolerance is plus or minus 0.5 for every 100mm, and the maximum forming size can reach 2m * 1m * 1m. The process is refined, and the mold can be formed in about an hour at the fastest, achieving rapid mold release. At the same time, Shenzhen industrial professionals focus on the research and application of silicone replica in the automotive field, aiming to provide automotive industry customers with exclusive services such as prototype production, rapid prototyping, small batch trial production, and customized modification of automobiles. They also provide one-stop rapid manufacturing solutions, making automotive research and development and manufacturing simpler, more efficient, more environmentally friendly, and at lower costs.