The OEM Silicone workflow can be divided into a number of distinct stages, starting with a concept sketch and culminating in a designed, manufactured and tested product. Knowing the expected timeframe can manage the expectations of product managers, engineers, and sourcing teams, and prevent them from facing unexpected expenses. When creating seals for automotive applications, gaskets for electronics, or custom parts for medical devices, understanding what happens is essential for a successful launch.
This guide details the typical workflow that happens when working with a silicone moulding manufacturer such as us on a custom moulding project. You will find real times for each stage with realistic time ranges, key milestones and factors that influence total time. Understanding the process helps you plan effectively for application-ready custom silicone parts and integrate them smoothly into your broader product development schedule.
Overview of the OEM Silicone Project Flow
While specifics differ from project to project depending on the complexity of the parts and their intended applications, most OEM silicone projects have a set of repeating steps. The key phases are:
- Define the requirements and develop a concept.Identify requirements and form a concept.
- This includes design and DFM review.
- Prototyping and pilot tooling.
- The test for validation and sample confirmation
- These are the production tooling and mass molding production.
Clear decision points all through each stage indicate that the project can proceed, stand still or adjust. Effective communication between your team and the manufacturer helps to speed up cycles and minimise risk.
Key Factors That Influence Project Timeline
There are many factors that can impact the duration of each stage:
- Part complexity: Time is added for tight tolerances, undercuts, multi-material overmolding or complex part geometries.
- Prototype quantities are sold at a faster rate than high volume quantities which require multi-cavity tooling.
- You can choose between compression molding, liquid silicone rubber (LSR) injection and co-molding, and each method offers varying lead times.
- Compliance requirements: Food grade, medical or flame retardant certifications require additional testing and documentation.
- Review cycles: Make sure you are getting quick feedback from you so that you don’t get bottlenecks.
Skilled manufacturers guide you with these aspects from earlier.
Stage 1 – Requirements and Concept Definition (1–2 Weeks)
All good work starts with a good foundation. During this first step, we compile all the information required to know your role and conditions.
Key activities include:
- Conduct a kick-off meeting or detailed briefing.
- Communicating useful specifications: operational temperature, chemical exposure, mechanical loads and regulatory requirement
- Checking out initial sketches, dimensions or reference samples
- Estimating volumes, targets and timelines
Milestone: Requirements Confirmed
Both teams now have a specification with proven performance requirements, material preferences and compliance requirements. With clear documentation here, you can minimize redesign loops later on and remain on track with your business goals.
Stage 2 – Design and DFM Review (2–4 Weeks)
With requirements locked, the focus shifts to detailed engineering.
Activities typically include:
- Developing or enhancement of 3D CAD models
- Full Design for Manufacturing (DFM) analysis including wall thickness, draft angles, parting lines and flash control.
- Grade selection of material – (e.g., Shore hardness, colour, FDA/LFGB compliance)
- Advisory on process recommendations for volume and performance requirements.
- The time of the design freeze and approval of the Design for Manufacturing is the milestone.
Milestone: Design Freeze and DFM Approved
The design is now settled and is ready to be prototyped. All DFM feedback has been taken into account, material, and process selection confirmed, and safe tooling design is now possible. Once these milestones are passed, changes are likely to increase costs and delays.
Stage 3 – Prototyping and Pilot Tooling (2–6 Weeks)
Most projects are validated with physical parts before making expensive production tooling decisions.
Typical steps:
- Prototype Mold Design and Making by CNC.
- If the surface is to be textured or polished, do so as specified
- Making up initial prototypes by compression or LSR methods.
- Dimensional inspection and functional testing, which are used to verify the range of motion, are required.
Milestone: Prototype Approved for Validation
Prototypes satisfy the scope of function, form and fit requirements. Your team will agree that they can go forward with them, and agree a design path before making the investment.
Stage 4 – Validation Testing and Sample Confirmation (2–6 Weeks)
This step is particularly significant for regulated industries, ensuring that the part functions consistently under actual conditions.
Activities often cover:
- Mechanical tests (tensile, compression set, tear strength)
- The product is subjected to environmental testing and aging tests.
- Compliance testing (biocompatibility, food contact, RoHS etc.)
- Samples that are to be used for the client’s evaluation that are as close to the production as possible.
Milestone: Customer Confirms Sample and Approves Production
Samples conform to all specifications for color, durometer, finish and performance. Production tooling is started when final approval is given.
Stage 5 – Production Tooling and Mass Molding Production (4–12 Weeks)
Once approved, the project is fully developed for manufacture.
Key steps:
- Final multi-cavity production mold fabrication (steel selection, cavity layout, cooling channels)
- Optimization of the process parameters and first article inspection.
- Surface treatments like silk screen printing, spray coating or laser engraving.
- Full inspection, quality control (IPQC / OQC), packaging and shipping.
- The students perform well and are well prepared for this event.
Milestone: Mass Production Start and First Delivery
Concept to Production is a typical timeline that is used for many projects.The typical Overall Timeline – Concept to Production.
Typical Overall Timeline – From Concept to Production
If you add them up, you’ll have a realistic picture:
- Requirements & concept: 1–2 weeks
- Design & DFM: 2–4 weeks
- Prototyping/pilot: 2–6 weeks
- Validation & sample: 2–6 weeks
- The production tooling & mass production process takes 4–12 weeks.
Simple projects with limited compliance can be in production in about 10-12 weeks. Parts that have complex parts and strict medical or automotive requirements can take 5-8 months. These ranges are based on actual experience, in hundreds of OEM projects.
How Volume and Compliance Affect Timeline
More expensive tooling is possible, but will take longer to qualify with higher volumes. As long as they are strict and it adds some testing time, it creates a long-term feeling of confidence. One of the greatest enablers for getting customers to respond quickly is at every review point.
Managing Timeline Risks and Delays
Slippage can occur for a variety of reasons, such as late design changes, slow sample feedback, unforeseen test failures or changes in tooling. It’s important to build reasonable buffer time and have open communication to keep things on track.
How to Keep Your OEM Silicone Project on Schedule
- Give all the necessary requirements and reference files beforehand
- Preserve the design prior to tooling by freezing the design.
- Start to schedule for validation testing early if compliance is needed
- Be quick to respond to prototypes/samples
- Work with a manufacturer that has extensive experience in your particular application field.
Summary – From Concept Sketch to Application-Ready Parts
A successful OEM silicone project is a logical process: Requirements definition, Design and DFM, Prototyping, Validation, and finally Production. The stage durations are 1 to 2 weeks, 2 to 4 weeks, 2 to 6 weeks, 2 to 6 weeks and 4 to 12 weeks. With knowledge of these milestones, and close collaboration, you have a chance of delivering high quality, application-ready custom silicone parts that meet on-time performance and commercial targets.
Careful time management is the key to avoiding frustration from delays and making a smooth launch. Should you have a concept sketch or project brief, our team is ready to review and create a detailed timeline according to your needs.
