Precision rubber molding for custom applications
Rubber molding is a complex process requiring in-depth knowledge of materials science, including the properties of different elastomers and their behavior under various conditions. Our expertise extends to understanding the effects of temperature, pressure, and material composition on the final product’s performance. For instance, the molding temperature significantly impacts the mechanical properties of the molded rubber, such as tensile strength and elongation at break. By optimizing these parameters, and more, we ensure that our products not only meet but exceed industry standards.
Furthermore, at KC Seals, we excel in the specialized manufacturing of rubber products through advanced molding techniques. Our capabilities include compression molding, transfer molding, and injection molding, each providing unique advantages suited to various applications.
Compression Molding This process involves placing preheated rubber into an open, heated mold cavity. The mold is then closed, applying pressure to shape the material accurately. Compression molding is particularly effective for producing large, durable parts with complex geometries and thick walls. The process ensures high precision and is cost-effective for lower volume production, making it ideal for customized and specialized components.
Transfer Molding Transfer molding begins by preheating the rubber and then transferring it into the mold using a plunger. This method allows for better control over material flow, reducing the risk of air entrapment and ensuring uniform distribution. It is suitable for producing small to medium-sized parts with intricate designs and tight tolerances, ensuring each part meets exact specifications.
Injection Molding Injection molding is a highly automated process where rubber is heated until pliable and then injected into a mold cavity under high pressure. This technique is excellent for high-volume production of small to medium-sized parts, providing consistent quality and precise dimensions. It minimizes waste and reduces cycle times, making it efficient and cost-effective for mass production.
Setup fees often become a significant barrier when considering a molded project. At KC Seals, we eliminate that hurdle by crafting all our rubber molds in-house, ensuring a faster and more cost-effective process. Plus, your intellectual property stays secure, without the delays and risks of outsourcing to unfamiliar machine shops. With KC Seals, everything happens swiftly and securely under one roof.
Relying on a single source for your molded rubber products can expose you to unexpected supply chain risks. Our Super-Sub program offers a fast and cost-effective multi-sourcing solution, minimizing the impact of potential disruptions. With no setup fees and minimal commitment, it’s the perfect safeguard for your moderate to high-usage production rubber parts, ensuring you stay ahead without slowing down.
Our integrated ERP/MES/QMS digital system adds unmatched flexibility to our production processes. With real-time visibility into work orders, production metrics, scheduling, supply chain management, and inventory, we can accurately predict delivery dates and swiftly adjust to any disruptions. This seamless integration ensures we keep your projects on track with speed and precision.
Our facility is home to a multitude of different presses with variable tonnage. We can manufacture standard sealing profiles to complex profile geometries. Below is a list of our basic guidelines which highlights some of our limitations. Download our design guide for a more detailed explanation of guidelines.
| SIZE | 16 inches in diameter and up to 10 inches in height. |
|---|---|
| VOLUME | 45 cu. in. |
| DEPTH | 4 in. from parting line |
| Up to 8 in. if parting line can pass through the middle of the part | |
| PROJECTED MOLD AREA | 175 sq. in. |
Tolerances: Are based on RMA “A2” standards which are commonly used in the Oil and Gas industry. Our design guide has a detailed table of RMA “A2” tolerances.
| Material Code | Application | Description | Temperature Range |
| NBR-WE130-B | General Purpose Nitrile (NBR, Buna) 80 Durometer | NBR 80 (Nitrile Butadiene Rubber), also known as Buna-N, is a versatile, cost-effective material widely used for general-purpose applications. It offers robust mechanical properties and basic resistance to many lubricants. NBR 80 performs well in applications needing FDA compliance and metal detectability, with good to excellent resistance to compression set, tear, abrasion, and substances like petroleum oils, hydraulic fluids, alcohol, water, silicone greases, Di-ester lubricants, and ethylene-glycol based fluids. It has a service temperature range of -30 to 250°F and meets ASTM 2000 M2BG710 specifications. However, it is not suitable for environments with ozone, UV, weathering, certain fuels, and solvents. For specific compound formulations, consulting with engineering is recommended. | -35°C to 120°C (-30°F to 250°F) |
| NBR93100-B | General Purpose Nitrile (NBR, Buna) 90 Durometer | NBR 90 (Nitrile Butadiene Rubber with a durometer hardness of 90 Shore A) is a highly durable material suited for demanding applications requiring resistance to wear, deformation, and mechanical stress. It excels in environments with oils, fuels, and various chemicals, maintaining integrity under high pressure and mechanical loads due to its superior load-bearing capacity and dimensional stability. However, NBR 90 is not suitable for exposure to ozone, UV, weathering, certain fuels, and solvents. For optimal performance, consulting with engineering for the appropriate compound formulation is recommended. NBR 90 is ideal for applications needing high durability and mechanical strength in industrial settings. | -35°C to 120°C (-30°F to 250°F) |
| HSN83002-B | General Purpose Hydrogenated Nitrile Butadiene Rubber (HSN, HNBR) 80 Durometer | HNBR 80 is a high-performance synthetic rubber known for its excellent resistance to heat, chemicals, and mechanical stress. Created by hydrogenating NBR, it offers enhanced durability against degradation from heat, oil, and chemical exposure. HNBR 80 is ideal for demanding applications, providing superior resistance to petroleum-based oils, fuels, aliphatic hydrocarbons, silicone oils, greases, and ethylene glycol. It also withstands hot water, steam, and diluted acids and bases, operating effectively from -40°F to 325°F. The harder durometer increases durability and load-bearing capacity, making it perfect for high-pressure applications, with improved abrasion and extrusion resistance for longer service life. However, it should be avoided in environments with highly polar solvents like acetone, ozone, UV, and weathering conditions. HNBR 80 is a cost-effective alternative to more expensive fluorocarbon elastomers, commonly used in automotive, industrial, and oil and gas applications. | -40°C to 150°C (-40°F to 302°F) |
| HSN93001-B | General Purpose Hydrogenated Nitrile Butadiene Rubber (HSN, HNBR) 90 Durometer | HNBR 90 (Hydrogenated Nitrile Butadiene Rubber with a durometer hardness of 90 Shore A) is a high-performance material known for its exceptional durability and resistance to heat, chemicals, and mechanical stress. It excels in applications involving petroleum-based oils, fuels, aliphatic hydrocarbons, silicone oils, and greases. Operating effectively from -40°F to 325°F, its increased hardness provides superior abrasion and extrusion resistance, ideal for heavy-duty uses. Not recommended for highly polar solvents and ozone, HNBR 90 is widely used in automotive, industrial, and oil and gas sectors. | -40°C to 150°C (-40°F to 302°F) |
| MCM3008-B | Swell Resistant HNBR 80 Durometer | MCM3008 is an advanced 80 durometer Hydrogenated Nitrile Butadiene Rubber (HNBR) compound specifically formulated for applications requiring exceptional chemical resistance and durability. The peroxide curing process enhances its resistance to high temperatures and aggressive chemicals, making it ideal for use in harsh drilling environments, such as oil-based muds (OBMs), inverts, and brines. This compound’s notable feature is its exceptional swell resistance, which ensures reliable performance and longevity even when exposed to various fluids commonly encountered in drilling operations. With a high tensile strength of approximately 4000 psi, MCM3008 demonstrates superior robustness and mechanical strength, essential for maintaining integrity under challenging conditions. | -35°C to 160°C (-30°F to 320°F) |
| MCM3009-B | Swell Resistant HNBR 90 Durometer | MCM3009, a 90 durometer HNBR compound, is a peroxide-cured material engineered for high chemical resistance and superior performance in demanding environments such as oil-based muds (OBMs), inverts, and brines common in drilling applications. This HNBR compound is known for its exceptional swell resistance in various fluids and boasts a high tensile strength exceeding 4000 psi, highlighting its robustness. With a service temperature range of -35°C to 160°C (-30°F to 320°F), MCM3009 is an outstanding choice for applications requiring strength, durability, and chemical resilience. | -35°C to 160°C (-30°F to 320°F) |
| 15760-B | Extrusion Resistant HNBR (HSN)
| The 15760-B is a newly developed 90+ durometer HNBR compound specifically designed for exceptional extrusion resistance. Its high durometer of 90+ Shore A contributes to its rigidity, significantly reducing deformation and preventing extrusion into gaps and clearances. Additionally, with a high modulus of elasticity, the 15760-B exhibits superior stiffness, further enhancing its resistance to mechanical deformation. While the optimized formulation includes specific fillers that increase the compound’s mechanical strength and stability. This combination ensures that 15760-B maintains its integrity under extreme conditions, making it an ideal choice for demanding applications in the oil and gas industry. | −450°F to 500°F (−270°C to 260°C) |
| 354260-B
| API 11D1 Approved HNBR (HSN) 80 Durometer
| The 354260-B compound, an HNBR material with an 80 durometer hardness, has successfully passed rigorous testing under conditions corresponding to API 11D1 V3, and V0 grades. This API standard encompasses stringent requirements for downhole equipment, specifically focusing on packer elements and other sealing components used in the oil and gas industry. Achieving V3 and V0 grade certifications under API 11D1 indicates that this HNBR material possesses exceptional mechanical properties and durability, demonstrating a remarkable capacity for maintaining seal integrity even under the high-pressure and high-temperature conditions typical of downhole environments. The ability of the 354260-B compound to operate effectively across a wide temperature range of -35°C to 160°C (-30°F to 320°F) further emphasizes its adaptability and resilience. The successful adherence to such a reputable standard is a testament to the compound’s superior quality, making it a formidable choice for critical applications in the demanding field of oil and gas extraction and production. | -35°C to 160°C (-30°F to 320°F)
|
| 115881-B
| API 11D1 Approved HNBR (HSN) 90 Durometer
| The 354260-B compound, an HNBR material with an 90 durometer hardness, has successfully passed rigorous testing under conditions corresponding to API 11D1 V3, and V0 grades. This API standard encompasses stringent requirements for downhole equipment, specifically focusing on packer elements and other sealing components used in the oil and gas industry. Achieving V3 and V0 grade certifications under API 11D1 indicates that this HNBR material possesses exceptional mechanical properties and durability, demonstrating a remarkable capacity for maintaining seal integrity even under the high-pressure and high-temperature conditions typical of downhole environments. The ability of the 354260-B compound to operate effectively across a wide temperature range of -35°C to 160°C (-30°F to 320°F) further emphasizes its adaptability and resilience. The successful adherence to such a reputable standard is a testament to the compound’s superior quality, making it a formidable choice for critical applications in the demanding field of oil and gas extraction and production. | -35°C to 160°C (-30°F to 320°F)
|
| 460360-B
| General Purpose FKM 80A (Fluoroelastomer, Viton®)
| FKM (Fluoroelastomer) is an exceptional sealing material valued for its high-temperature resistance and compatibility with various chemicals. It operates efficiently within a temperature range of -26°C to 204°C (-15°F to 400°F), making it suitable for high-temperature environments and/or applications demanding chemical resistance. FKM seals are resistant to an array of substances including HFD-S and R fluids, mineral, vegetable, silicone, and biodegradable oils, hydrocarbons, alcohols, diesel, gasoline, fuels, ozone, oxygen, and air up to 200°C. However, they are not resistant to steam. Commonly used for both static and dynamic sealing applications, FKM is ideal for standard and special seals, wipers, O-rings, flange seals, and rotary seals, as well as for rubber energizers or preload elements in various sealing configurations. Its resilience in facing extreme conditions is why FKM is the preferred choice in industries that prioritize longevity and reliability, such as aerospace, automotive, and chemical processing. | -26°C to 204°C (-15°F to 400°F)
|
| 441360-B
| General Purpose FKM 90A (Fluoroelastomer, Viton®)
| FKM (Fluoroelastomer) is an exceptional sealing material valued for its high-temperature resistance and compatibility with various chemicals. It operates efficiently within a temperature range of -26°C to 204°C (-15°F to 400°F), making it suitable for high-temperature environments and/or applications demanding chemical resistance. FKM seals are resistant to an array of substances including HFD-S and R fluids, mineral, vegetable, silicone, and biodegradable oils, hydrocarbons, alcohols, diesel, gasoline, fuels, ozone, oxygen, and air up to 200°C. However, they are not resistant to steam. Commonly used for both static and dynamic sealing applications, FKM is ideal for standard and special seals, wipers, O-rings, flange seals, and rotary seals, as well as for rubber energizers or preload elements in various sealing configurations. Its resilience in facing extreme conditions is why FKM is the preferred choice in industries that prioritize longevity and reliability, such as aerospace, automotive, and chemical processing. | -26°C to 204°C (-15°F to 400°F)
|
| FKM80BRN-B
| Brown FKM 80A (Fluoroelastomer, Viton®)
| The FKM80BRN-B, a brown Fluorocarbon elastomer widely known by the trade names VITON® and FKM, is an advanced sealing material recognized for its formidable resistance to heat, hydraulic fluids, chemicals, and various organic compounds. It exhibits exceptional performance in temperatures ranging from -25°C to 210°C (-13°F to 410°F). FKM seals are resistant to an array of substances including HFD-S and R fluids, mineral, vegetable, silicone, and biodegradable oils, hydrocarbons, alcohols, diesel, gasoline, fuels, ozone, oxygen, and air up to 200°C. However, they are not resistant to steam. Commonly used for both static and dynamic sealing applications, FKM is ideal for standard and special seals, wipers, O-rings, flange seals, and rotary seals, as well as for rubber energizers or preload elements in various sealing configurations. Its resilience in facing extreme conditions is why FKM is the preferred choice in industries that prioritize longevity and reliability, such as aerospace, automotive, and chemical processing. | -25°C to 210°C (-13°F to 410°F),
|
| FKM90BRN-B
| Brown FKM 90A (Fluoroelastomer, Viton®)
| The FKM90BRN-B, a brown Fluorocarbon elastomer widely known by the trade names VITON® and FKM, is an advanced sealing material recognized for its formidable resistance to heat, hydraulic fluids, chemicals, and various organic compounds. It exhibits exceptional performance in temperatures ranging from -25°C to 210°C (-13°F to 410°F). FKM seals are resistant to an array of substances including HFD-S and R fluids, mineral, vegetable, silicone, and biodegradable oils, hydrocarbons, alcohols, diesel, gasoline, fuels, ozone, oxygen, and air up to 200°C. However, they are not resistant to steam. Commonly used for both static and dynamic sealing applications, FKM is ideal for standard and special seals, wipers, O-rings, flange seals, and rotary seals, as well as for rubber energizers or preload elements in various sealing configurations. Its resilience in facing extreme conditions is why FKM is the preferred choice in industries that prioritize longevity and reliability, such as aerospace, automotive, and chemical processing. | -25°C to 210°C (-13°F to 410°F),
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