Designing products that incorporate liquid silicone rubber requires a different mindset than working with conventional plastics or metals. The material’s flexibility, flow characteristics, and curing behavior all impact how designers should approach their projects. When done correctly, the results are reliable components that perform in demanding environments with unmatched precision.
Key Design Considerations
Wall Thickness
Thin sections allow fast curing but may risk tears if too delicate.
Consistency in thickness reduces internal stress and warping.
Flow Characteristics
Because LSR has a low viscosity, it can fill complex cavities and thin sections easily.
Proper venting in the mould prevents trapped air and improves surface finish.
Parting Lines and Flash
Silicone can seep into microscopic gaps. Designers must account for tight mould tolerances to avoid excess flash.
Undercuts and Overmoulding
Flexible properties allow undercuts to be moulded without damaging the part.
Multi-material overmoulding combines the strengths of rigid plastics with soft silicone features.
Prototyping and Testing
Rapid prototyping with LSR allows designers to test functionality early in development. Tools such as 3D printing inserts or prototype moulds make it easier to validate dimensions, flexibility, and usability before committing to large-scale tooling.
Case Examples
Medical Devices: Incorporating thin membranes for sensors while ensuring durability.
Consumer Electronics: Designing gaskets that seal against dust and water without adding bulk.
Automotive Seals: Creating geometries that maintain elasticity under compression and temperature cycling.
Optimising for Manufacturing Efficiency
Designing for manufacturability reduces cycle times and costs. Automated demoulding, minimal secondary finishing, and efficient cavity layouts all contribute to productivity.
By following best practices, designers unlock the full potential of liquid silicone moulding. It’s not just about creating a part—it’s about engineering components that thrive where others fail.