Compression molding: the workhorse for standard parts
In compression molding, a pre-formed silicone blank is placed into a heated mold and pressed into shape. It has low tooling costs and works well for simple, sturdy parts like O-rings, gaskets, straps, and diving masks. Cycle times are longer and flash lines are more visible, but for medium volumes it remains the most cost-effective choice.
Liquid silicone rubber (LSR) injection molding
LSR injection molding pumps liquid silicone into a closed mold under high pressure. It produces precise, flash-free parts with excellent consistency, which is ideal for complex geometries, thin walls, and high-volume consumer products like baby soothers and phone cases. Tooling is more expensive, so LSR makes sense when you need tight tolerances at scale.
Extrusion: continuous profiles and tubing
Extrusion pushes uncured silicone through a shaped die to create continuous lengths such as sealing strips, tubes, and hoses. It is perfect for window seals, cable gaskets, and silicone tubes that are later cut to length. Extruded profiles can be joined into endless rings or co-extruded with harder materials for specific sealing jobs.
How to choose the right process
Match the process to your product geometry, annual volume, and tolerance needs. Simple flat parts under 100,000 pieces a year suit compression molding. Complex, high-precision parts favor LSR. Continuous profiles and tubing require extrusion. Share your drawings with the factory and ask for a process recommendation with a cost breakdown for tooling and unit price.
Process transparency matters for quality
Ask your factory which process they recommend and why, then request sample parts made on the actual production line. Watch for consistent flash removal, clean parting lines, and uniform color. A factory that explains process trade-offs honestly is more likely to deliver parts that match your samples at scale.
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