Silicone Rubber Thin Walled Disc Valves

Using our background in the medical industry and combining it with our technically strong workforce, Elastomer Technologies produced the disc valve highlighted here. Designed for use in eye surgery equipment, part thickness transitioned from 0.050″ to 0.010″ over a 0.500″ diameter. With +0.000″/-0.003″ tolerance requirement, this job presented challenges in tooling design, process engineering, and quality management. With our past record of success, the client was confident that we would meet their high quality expectations.

To achieve the required accuracy and consistency on an exceptionally thin-walled part, we stretched the limits of the injection molding process to the extreme. We took the time up front to develop a tooling design that would ensure repeatable production and an acceptable yield rate. Our engineers arrived at a solution that featured a gate on the outside of part diameter to optimize the accurate flow of material into the mold. This necessitated venting in the center of the part using a pin, which we configured in a way that avoided any possibility of flash forming along the part’s edges.

Using a 50-ton all electric molding press and medical-grade liquid silicone rubber, we closely monitored all aspects of production to ensure process repeatability and a very low reject rate. One-hundred percent process verification and validation right at the machine ensured that the products packaged and shipped to the client met their strict quality criteria. By approaching this project with our usual focus and agility, we were able to complete it within a narrow timeframe. Ongoing production involves orders from 2,000 to 4,000 units, which we turnaround on a two or three week schedule.

To learn more about this project or our exceptional process capabilities, contact us today.