Design

RESEARCH & DEVELOPMENT

It all starts from our R&D area where we regularly invest our time & effort to play with the physical properties of an elastomer to with-stand harsh environments either that be Temperature, Oil, Load, Sea Water or any other.

With advance testing equipments, tools and technical expertise of our team we are capable to test components from raw material stage to mixing, moulding and final quality test.

DESIGN

Our preference is always to be involved from the very early stages of the component design that can save both time and money.

This is how our product design team can help:

  • Elastomer selection: Making sure the right elastomer is selected for the job
  • Process Selection: Depending on the characteristics required of the finished product selecting the right process either Compression, Injection, Transfer or extrusion
  • Tooling & Mould design: Along with our industry recognised partners, we are able to design and machine tooling and moulds for vast range of rubber components from 1gm up to 30kgs.
  • Designing & producing prototypes using reverse engineering incase design files are not available.
  • Designing & producing prototypes from 2D & 3D CAD drawings where we can offer 3D printing in the latest “rubber like” materials to give feel of the component or 3D printed models in hard plastic to illustrate shapes.

work process

Process Selection

Rubber Products can be manufactured using a wide variety of processes and it is important that the correct process is selected.

This selection takes into account the charactheristics required of the finished product along with the volumes of the part required. When saini rubber receives an enquiry our expert team will review it and select the best manufacturing option for example:

  • Moulding Type: Compression, Transfer, Injection
  • Rubber to Metal Bonding
  • Extrusion. Continuous Cure – Autoclave
  • Extrude and Cut to Length
  • Extrude and Vulcanise into Rings or Frames
  • Cutting from Sheet material. Punching – Water Jet Cutting

Saini Rubber can also offer a variety of post processing/ finishing operations.

  • Cryogenic Deflashing
  • Hand Trimming
  • Cutting to Length and Joining – Vulcanised Joints and Cold Bonding
  • Applying Self Adhesive Backings
  • Buffing
  • Painting – Applying Slip Coats

It is also necessary to consider both the tooling and finished product cost as the process selected can influence this considerably.

We have the expertise to guide and advise our customers on the various options available to achieve a cost effective solution for the manufacture of their part.

Development & Support

Saini Rubber is able to offer Development and Support from Concept to Production.

After initial review of your design Saini Rubber has material technologists and engineers with rubber processing experience that can support the product development through from initial sample submission to full production.

  • Saini Rubber can offer to manufacture 3D printed models in a ‘rubber like’ material
  • Prototype Tooling and fully functional parts in various materials for evaluation and testing
  • Assistance and guidance with any subsequent adjustment or design change
  • Saini Rubber will review the process to ensure the most cost effective method of manufacture conducive to the product has been selected

It is also necessary to consider both the tooling and finished product cost as the process selected can influence this considerably.

Without any compromise in quality and for larger volume, price sensitive products.

We can then design and manufacture production tooling to meet the desired volumes and any cost constraints. For example a larger number of cavities will increase tooling costs but may reduce final part prices.

Material Selection

The variety of polymers available can lead to several options when making a preliminary choice of material for your Rubber Moulding.

We are very aware that careful selection of the elastomer is essential to ensure that all design criteria are met. When selecting the type of rubber to be used it is necessary to consider some or all of the following:

  • Mechanical Properties i.e. Hardness, Tensile strength, Compression set.
  • Electrical Properties i.e. Resistivity, Conductivity.
  • Thermal Properties i.e. Hot, Cold, Fire retardant.
  • Environmental Properties i.e. Oil, Acid, Ozone and Weather resistance.
  • Costs – some materials are much more expensive than others requiring careful selection for the application.
  • Process to be used i.e. Thermoplastic Rubber Moulded on Conventional Plastic Injection Equipment for High Volumes or Compression Moulding for Single Cavity Tooling.

We recommend that our Technical Department is involved at the earliest opportunity. Together with Product Designers and Engineers, we can evaluate all the aspects of the products service requirements and offer a cost effective compound/ solution that will optimise the manufacturing and desired service parameters.

Saini Rubber has a wide range of rubber compounds meeting many Industrial specifications including British, European and American standards, Automotive, DVGW, MOD, WRAS and FDA requirements.

  • EPDM compounds WRAS approved for cold water and hot potable use. Also approved to the requirements of the German and French water industry.
  • Nitrile compounds approved to EN 682 for gas applications.
  • Fluorocarbon (FKM) and Hydrogenated Nitrile (HNBR) compounds approved for use in Wellhead safety equipment

We have the expertise to guide and advise our customers on the various options available to achieve a cost effective solution for the manufacture of their part.

Tooling Design

Saini Rubber's Technical Team along with our well established Partners are able to Design and Manufacture Tooling and other equipment required for the manufacture of the vast range of Rubber Components from less than 1 gram up to 40 Kilos.

We can Manufacture Tooling from Single Cavities for Prototypes or Low Volume Production through to fully hardened Multi-Cavity Tools for High Volume Production. We manufacture tools for:

  • Compression Moulding
  • Transfer Moulding
  • Injection Moulding both Thermoset Rubber and TPE
  • Corner Moulding and Jointing of Extrusions
  • Sponge Rubber

Saini Rubber are able to work from samples (see Reverse Engineering section) 2D Drawings of full 3D CAD Data of the required component to design, and manufacture tooling best suited to the application be it large or small volumes

Saini Rubber can accept CAD Data in a variety of formats including:

  • DXF, DWG, STP, IGS, x_t

Our toolmakers are equipped with the latest CAD/CAM software. They have CNC machine tools and all the necessary ancillary equipment you would expect to find in a modern tool room. They also have CMM (coordinate measuring machines) for the inspection of the finished tools.

Prototyping

Saini Rubber is able to offer a first class Prototype facility.

Once the initial component design has been established Saini Rubber can take the project to the next stage. Using our in house expertise and our established strategic partners working either from samples, 2d drawings or 3d CAD data we can offer:

  • 3D Printed models in hard plastic to illustrate shapes
  • 3D printing in the latest “rubber like” materials to give some idea of the feel of the part
  • 3D printing of a soft tool and casting the component in a flexible rubber material
  • Manufacture of a prototype tool to manufacture the part in the correct material producing a fully functional component. This can also be used for low volume production

Saini Rubber often recommend making prototypes as they can help establish both materials and processes suitable for volume production giving a high degree of certainty that the final design will work before money and time are committed to expensive production tooling

Saini Rubber working closely with a Customer at the early stage of rubber moulding development will reduce cost and improve component function derived from our thorough understanding of materials and their performance characteristics.

We have the expertise to guide and advise our customers on the various options available to achieve a cost effective solution for the manufacture of their part

Reverse Engineering

Saini Rubber can offer this service when the original Drawings or CAD Data have been lost or are no longer available but there is a sample part.

Working from a sample we can:

  • Identify the rubber used
  • Measure the hardness of the rubber
  • Measure the dimensions of the part using conventional and Non-Contact measuring methods such as CMM (coordinate measuring machine) and Shadowgraph.

If the part is more complex or requires a greater degree of accuracy we can 3D Laser Scan the part. This process can produce a highly accurate 3D model that can be used to manufacture a mould tool to be able to reproduce the part

Saini Rubber has used Reverse Engineering to produce one off speciality parts for Classic Cars and Military Vehicles along with low volume Train Door seals for Rolling Stock refurbishments amongst others.

This technique has enabled Saini Rubber to make large and small parts including Gaskets, Diaphragms, Bellows, Gaiters, Rubber to Metal Bondings, Window and Door Seals

We have the expertise to guide and advise our customers on the various options available to achieve a cost effective solution for the manufacture of their part.

Product Feasibility

Saini Rubber will help you establish if rubber is the most suitable material for your application we are then able to:

  • Review your product to select the best grade of material for your application.
  • Select a manufacturing process suitable to achieve the design criteria
  • Select a cost effective method of production

Saini Rubber with our strategic partners are able to offer 3d modelling and printing in rubber like materials.

Prototype tooling and fully functional prototype parts.

We are also able to offer a reverse engineering service where no drawings or CAD data is available.                                                                                      

Product Design

Saini Rubber is always pleased to be involved in the very early stages of your Product/ Component Design. If the design of the part is critical, Saini Rubber will use all it's rubber processing experience to achieve what is required of the component using the most cost effective manufacturing methods.

But sometimes, a new component design seen through the eyes of our highly experienced Materials Technologist, Production Engineers and Manufacturing Managers can, where functionality and aesthetics allows, be adjusted to achieve a more cost effective product.

Saini Rubber can assist with:

  • Advice on product shapes to make any tooling simpler and easier to manufacture
  • Material Selection – choosing the material best suited to give optimum performance at the best price
  • Designing the component so the lowest cost manufacturing process can be used but still maintain the functionality of the part
  • Analysis of the component price and the tooling cost for the required volumes to achieve the most cost effective solution
  • Prototypes – fully functional parts in the selected material
  • 3D Printing in “rubber like” materials
  • Reverse Engineering

WE PROVIDE FULL DIMENSION AND MATERIAL CONFORMITY TO ISO 9001 CERTIFICATION

We are here to help!