Custom Gasket Mfg. is a leading supplier of rubber extrusion services for a wide range of industries and applications worldwide.
The rubber extrusion process is often combined with additional post-cure procedures including splicing, vulcanizing, steam curing, continuous curing, cutting to length, and lathe cutting.
Custom Gasket Mfg. specializes in high-quality custom rubber extrusions in all rubber compounds and elastomers. Our company’s reputation for excellence has been built on our ability to provide our valued customers with the most effective manufacturing solutions to meet their most demanding applications. Custom Gasket Mfg. is committed to consistently providing precision custom rubber extrusions and extruded rubber products to meet all of your blueprint and tolerance specifications.
Rubber Extrusion Process
The rubber extrusion process involves forcing a rubber compound or mixed elastomer under pressure through a die that has the shape of the end product. The process starts with feeding material into an extruder, where heat and pressure are applied to aid the material’s travel through the die. Depending upon the material used, the heat and pressure will expand the end product’s size.
Vulcanized rubber is a natural elastomer that has been made more durable by a biochemical process that cures the rubber. During vulcanization, the rubber is combined with a curing ingredient, usually sulfur and heated under pressure. In its simplest form, vulcanization is brought about by heating rubber with sulfur. Vulcanization is a treatment process for natural rubber that makes it much more durable and suitable for a wider range of applications. In order for the product that comes out of the extruder to shrink to the appropriate size, Custom Gasket Mfg. uses a variety of vulcanization techniques such as; steam curing, continuous curing, and cutting-to-length.
Steam curing is mainly used for smaller batches and when the material being used contains non-black compounds. Curing with steam rather than with chemical cures is advantageous because it is considered a safer way to vulcanize rubber. Through steam curing, materials have significant wear performance properties, especially when using bonding in future installations.
Continuous curing is used on larger quantities or larger physical sizes of products. This technique uses microwaves or salt bath processes to gradually cure the rubber. Continuous curing is a low-energy technique because only a small amount of energy is applied over time. This process also ensures a greater consistency of the profile of the end product.
Cutting-to-length is used to cut material away to achieve the desired shape of the end product for close tolerances. Lathes, high-speed cutters, and rotating cutters are used on longer runs and larger physical sizes of products. Other cutters can be used on long continuous runs and guillotine cutters are used on long-length and larger cross-sections.
Splicing is used as a more cost-effective way to produce an endless loop product with an extruded profile or other products with complex corners because it requires no expensive custom tooling or dies. The process starts by utilizing our other methods of production to make the components of the final product. These components are cured using one of our curing techniques and cut, if needed, for final assembly. Depending on the desired shape of the final product, the materials can be spliced using cold bonding or splice molding.
Hot Splicing / Vulcanizing
Custom Gasket Mfg. uses the hot splicing/vulcanizing process to chemically bond two ends of rubber extrusion together. This creates an endless seal making the gasket stronger and more impermeable to the elements.
Rubber Lathe Cutting
The lathe cutting process involves extruding a tube of rubber, cutting it to a specified length and sliding it on to a mandrel. The part is then grinded at high speed on the outside dimension (OD) using a lathe. Custom Gasket Mfg. uses state-of-the-art lathes and grinding equipment to finish the outer surface to your precise tolerance. Parts that are suited for lathe cutting are washers and gaskets requiring precision to high precision tolerances. Most materials available today can be produced using the lathe cutting process. Some of the advantages of lathe cutting are no tooling cost, minimal waste, no flash, no die cut concavity (hour-glassing), and an excellent static face sealing surface.
Rubber Extrusion Materials
Custom Gasket Mfg. has an extensive selection of rubber compounds to choose from. The most common rubber elastomers we use include:
Custom Gasket Mfg. has the ability to custom formulate compounds for your specific applications. Custom color compounding is available upon request.
Please visit our gasket materials page for more information on our extensive selection of materials.