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LSR injection moldingFrom preliminary analysis to mass production: continuous improvement and performance factors

Silicone Elastomers World Summit 201728-29 November 2017, Munich, GermanyMarco Canova

Challenges of the Market

• Complexity of Products increases• Demand from Customers are ever more stringent• Increase the competitiveness in the global market

CustomerSatisfaction

• Directly from the Drawing to the Product

• Not all aspects are evident only from the Drawing

• Corrective actions needed

The Past

Strict cooperation between customer and supplier gets always more important in all new product-related steps:• Preliminary analysis of new project• Prototype phase• Series production

Present and Future

• Burr

• Tool divisions

• Tolerances

• Injection Point

The Drawing

• Experience• SIGMASOFT® Virtual Molding / Injection Simulation

Detecting critical issues

Injection Point

Comparing Solutions

• Sharing the most information possible

• Knowledge of operating conditions

• Ex.: ensure sealing function bearing in mind interconnections with the other components (plastics/metal) with their own tolerances and also considering the assembly step

• FEM studies

Function / Assembly

Supporting the customer with our experience on raw material, depending on the application:

• Hardness• LSR grades• Self-lubricating – connectors seals and gaskets• Self-adhesive – 2K products• Ultraclear – LED lenses• Fluorosilicone - resistance against fuel and oil• FDA compliant – food industry applications• USP Class VI compliant – medical industry

Choice of the right Raw Material

• Responsibility for the project• Maximum possible interaction

between all players• Definition of special

characteristics fundamental for LSR overmolding (ex. Value of surface tension in order to ensure adhesion)

• Extended competence on materials different from LSR required

Supply Chain Management

BuyerMainContractor

Supplier

Supplier1

Supplier2

Supplier3

Logistics / Packaging

Considering Logistics/Packaging aspects:• Cleanliness requirements• Avoiding damages• Blisters for

Aluminium overmoldings Ultraclear components for lighting

• Double PE Bag for medical applications• Special packagings

Series Production Orientation

There are many aspects to consider:• Delivering world-wide• High volumes projects• Quality target: Ø defects

Instruments:• Vision systems • Dimensional controls in automatic during

assembly step

Post-processing

Also the post-processing step is fundamental, for example post-curing with rotative and static ovens, which is required for:• Medical components • FDA compliance• Increasing mechanical

characteristics(ex: Compression Set)

Instruments

• Dedicated Human Resources• Mould project and construction• Process / Industrialization

Dedicated Human Resources

Highly skilled team dedicated to new projects, specialization on families of products

Mould project and construction

The mould project is one of the most important steps when starting a new project:• Internal development and construction

(over 500 LSR moulds for series production realized)

• Choice of materials and thermal and superficial treatments

• Cold Runner internal Know-How

Process / IndustrializationIn order to achieve the most from the mould and to reach the best possible OEE, following factors are essential:• Determine the correct injection

moulding machine for the product• Constant renewal of IMM and

accessories• Development of in-line automation

machines with multiple functions

PrototypingPrototyping is not always necessary, but if realized with the concept of series production can be very useful:

• Prototype moulds according to customer’s needs: from A-Sampling to series-like capacity

• In case of changes quick reaction time –target: Customer’s Time to Market

• Rapid Prototyping to reduce costs and delivery times

Series Production

• Action Learning• Continuous improvement

Action LearningDuring series production use all lessons learned from previous experiences:• Reduction of cycle times • New mould concepts• Real Process optimization with

Virtual Molding • Constant research on our own

cold runner system

Continuous improvement

Improvement means also research on new technologies:• New treatments to improve adhesion

over metals for 2K products: New cleaning technologies on

metals New pre-treatments before molding

• Multi-machine and multi-function feeding lines

IVG GroupIVG with more than 1.000 employees and since 1966 is leader in the production of more than 5.000 different types of flexible rubber hoses to convey powders, granular, liquid or gas products. Systems and services include the Oil & Gas sector, food, chemical, agricultural, construction, rail, naval and steel industries.Combine skills to spread professionalism.The IVG Group operates in four business areas:• rubber hose• rubber and plastic production• decoration and printing• mechanical applications and engineeringWeb: www.ivgspa.it

Silikoneurope S.r.l.

Headquarter Loiano, ITALY

Foundation 1975

Managing Director Angelo Santi

Certificates UNI EN ISO 9001:2008

ISO/TS 16949:2009

UNI EN ISO 14001:2004

web silikoneurope.it

Headquarter Sao Paulo, BRASIL

Foundation 2013

Managing Director Riccardo Colbachini

Certificates UNI EN ISO 9001:2008

web silikonbrasil.com.br

Silikonbrasil LTDA

Company Profile

Research and development for the construction of equipment and the manufacture of Technical Articles in Liquid Silicon Rubber (LSR) for over 30 years

Mobility

Lighting Industry

Food Industry

Life Science

Household Devices

Veterinary

Thanks for your attention!