Trelleborg accelerates small batch production of LSR parts

Trelleborg Sealing Solutions is supporting manufacturers with iCast LSR, a new fast and flexible digital manufacturing process for product development and small batch production of Liquid Silicone Rubber (LSR) parts.

Trelleborg’s iCast LSR process offers a cost-effective way for manufacturers to develop product variations or try out different design concepts before investing in serial production tools. In addition, the process enables the start of pre-series and series production with small batches, to close the gap between low and high-volume production.

Felix Schädler, project manager for innovation and technology at Trelleborg Sealing Solutions, says: “iCast LSR is an adaptable five-step modular process that utilises digitisation and new manufacturing techniques. It can dramatically cut concept to production time for prototypes from several weeks to a few days for the average part. This helps manufacturers meet the pressures of rapidly moving markets that are demanding faster new product introductions, improvements, and advancements.”

The Trelleborg iCast LSR process starts with the submission of 3D part data and order details. A feasibility study based on artificial intelligence (AI) is triggered to confirm if the iCast LSR process is suitable for production of the part. Upon completion of the feasibility study, the part design is analysed, and the individual digital mould layout is created based on 3D data. If necessary, this undergoes mould flow simulation. In a virtual environment, this process identifies the optimum production process for the use of additive manufacturing (AM) technologies in order to achieve the best possible quality.

With iCast LSR technology, quick and multiple design iterations of components in standard industrial grade two-component platinum-cured LSR can be made. These demonstrate the properties and quality levels of high-volume injection moulded parts. Currently suitable for production of one to 2,500 parts, Trelleborg’s iCast manufacturing process can be utilised to produce a wide range of 2-D and 3-D LSR components including O-Rings, profile seals, diaphragms and custom-moulded parts.