Creating a silicone product concept to become a real, production-ready part is one of the most exciting and difficult stages in product development. While there are many great ideas which never make it to the market because the transition from sketch to a manufacturable silicone part requires careful alignment of the function, material performance, design feasibility and choice of process. We at Dongguan HT Silicone & Rubber Co., Ltd., have walked hundreds of brands, engineers and OEM buyers through this very process, helping them to avoid common pitfalls and provide reliable, quality silicone solutions.
From making a new kitchen gadget to a car’s seal, medical parts, or a promotional item, the common denominator is that there is a process to work through. From requirements to full-scale production, this guide takes you through the practical steps to bring your idea for silicone application to a manufacturable product with confidence and turn your silicone application idea into a manufacturable product with confidence. For more inspiration across industries, explore our applications.
Step 1 – Define the Application Problem and Requirements
Taking the time to explicitly define the objective for the silicone part and the conditions it will encounter before any lines are drawn and materials are selected will reap many benefits. If we take the time to read the requirements, we will almost always find that it is not specific enough and will result in multiple redesign cycles, tooling costs, and delayed launches.
Look at these key questions and reflect on them:
- What is the main purpose of the part? (Sealing, cushioning, gripping, insulating, or protecting?
- What kind of environment will it be exposed to, e.g., temperature extremes, chemical exposure, UV light, vibration, pressure, etc.?
- Who/what will it come into contact with—food, skin, medical fluids, or no one?
- Do you require regulatory/compliance requirements such as food-grade, biocompatibility or flame resistance?
Writing Down Requirements in a Simple Specification Sheet
Prepare a one page specification sheet that documents:
- Performance parameters (hardness, compression set, tensile strength)
- Dimensional envelope and critical interfaces
- Limitations imposed by the environment and regulations.
- The volume of production expected and the target cost.
At this point, having clear documentation significantly decreases misunderstandings when dealing with your silicone manufacturer later on.
Step 2 – Translate Requirements into Rough Part Concepts
If the requirements are documented then move to rough concepts. This may involve hand sketches, basic 3D models, or even foam models demonstrating overall shape, attachment points and part interactions with other parts.
Work on practical geometry questions:
- How will the part fit together or be compressed?
- Where are the thick and thin sections?
- What actions or changes in shape does it need to repeat?
Involving Manufacturing Colleagues or a Silicone Partner Early
Even at this early stage, contact an experienced OEM/ODM silicone partner. Initial information on wall thickness, draft angles, possible undercuts and molding issues can be very cost and time-saving. Initial concepts are regularly reviewed and fast feasibility input is given based on proven real experience in production over 10 years at HT Silicone.
Step 3 – Material Selection: Matching Silicone Grade to the Application
Silicone doesn’t come in one size fits all. The performance of various formulations varies significantly and should be based on specific requirements.
Key considerations include:
- Temperature performance (grade standard, high heat up to 230°C, or low temp grades)
- Resistance to chemicals (oils, fuel, cleaning agents and water)
- Contact requirements: food grade, medical grade, skin safe
- Mechanical properties – hardness range, elasticity, tear strength
When Medical, Food-Grade or High-Temperature Grades Are Required
For food contact items, FDA or LFGB approved materials, complete with documentation are generally required. In the medical field, low extractable, biocompatible grades are required that comply with ISO 10993. Fluorosilicone or high-temperature VMQ compounds might be required for automotive or industrial parts. Selecting the correct grade guarantees compliance with regulations as well as reliability over a long period, without the risk of expensive failures in the field.
Step 4 – Choosing the Right Processing Method for Your Part
The manufacturing process plays an important role in cost, quality and design flexibility. Typical methods of silicone part molding include compression molding, liquid silicone rubber (LSR) injection molding and over molding.
Considerations to make when selecting:
- Part complexity and tolerances
- Production volume
- Surface finish requirements
- There is a need to integrate multiple materials.Multiple material integration is required.
When to Use Compression, LSR, or Overmolding
Simple shapes and medium production volume are appropriate for compression molding and it is cost efficient. LSR injection is ideal for high-volume production, complex designs, close tolerances and uniformity. For bonding silicone to plastic or metal substrates for integrated assemblies, the over molding process is most suitable. Our engineering team assists clients to determine the best process for the part and volume requirements.
Step 5 – Designing the Part for Molding and Assembly (DFM)
Design for Manufacturability (DFM) takes an idea that functions and makes it a part that will be reliable to mold. Silicone has special properties including flexibility and shrink, which must be taken into account in the design.
Typical DFM focus areas:
- A uniform thickness of the wall to avoid warping or voids.
- Correct tolerances (silicone will not offer metal tolerances)
- Ensure that the vent is properly positioned and the parting line is correctly cut.
Balancing Performance, Tolerances and Cost in the Design
Balancing Performance, Tolerances and Cost in the Design
Tight tolerances are not required for all dimensions. Only include critical tolerances where they are necessary to the function and take out where possible. This helps to simplify the tooling and part cost without compromising performance. Our partners who are experienced give you the detailed DFM feedback and practically suggest you how to improve.
Step 6 – Prototyping and Pilot Runs Before Full Production
Avoid going directly from design to the production tooling. Prototyping is a low-risk and low-cost way to validate fit, function and manufacturability.
Prototypes help confirm:
- The accuracy in terms of dimensions and the fit of the interfaces.
- Mechanical properties in response to load
- Initial material performance
Pilot runs with temporary tooling add further assurance of process stability prior to the investment in hardened production molds.
Step 7 – Validation Testing and Compliance Checks
Depending on the application, formal testing establishes that the part satisfies all of the requirements in real world conditions.
These typical tests include compression set, tensile strength, environmental cycling and regulatory compliance testing.
When Formal Compliance Testing Is Required
Typically, third party documentation is required for medical and food-contact products. Automotive parts can have particular performance requirements. You can conduct these tests early on, to ensure your silicone product will meet the legal and customer requirements without any surprises.
Step 8 – Finalizing Tooling and Preparing for Production
Once designs and materials have been validated, the project enters production tooling. At this stage, mold design, cavity layout, process parameters and quality inspection plans are solidified.
Key activities include:
- Optimising the mould cooling and venting
- Establishing in-process controls
- Identifying critical to quality features and sampling plans
Step 9 – Managing Production, Reorders and Long-Term Changes
When you’ve managed to launch your product, the work has only just begun. Known as a reliable partner, it guarantees a uniform product every batch, timely deliveries and seamless handling of future changes like colour, minor geometry modifications, material changeovers etc.
As the product evolves, robust version control and traceability ensures your brand is safeguarded.
From Idea to Product – A Practical Summary
These are the fundamental steps to successfully make an application idea a manufacturable silicone product:
- Setting an application’s requirements is essential.
- Create sketch ideas and get early comments
- Choose the most suitable grade of silicone for their application.
- Choose the best processing method
- Optimize design for manufacturability (DFM)
- Prototype and pilot to test
- Complete necessary testing and compliance
- Complete Production Tooling and Controls
- Coordinate and maintain continuous production and updates
All decisions should be based on your initial application requirements. By partnering with a manufacturer that is experienced like Dongguan HT Silicone & Rubber Co., Ltd. from the beginning, you can bring the high-quality silicone products to the market faster and cheaper, and reduce the risks in the process.
If you already have an idea for a silicone product, talk to our team about it. From design support to material selection, to mass manufacture, we stand with you, helping brands around the world to take their innovative ideas to market.
