The overmolding silicone mask for industry is made of PC, PA, PA66 and other materials + liquid silicone material.TYM has Complete set of LSR Injection molding solution for clients.
It is made by injecting liquid silicone into a plastic structure. This makes the mask softer and more comfortable to wear. It also makes the silicon mask for industry stronger. This means that fewer masks need to be made, which saves money.
The LSR overmolding process for the overmolded mask involves creating the plastic parts first, loading them into a liquid silicone mould, and then doing a secondary injection moulding of liquid silicone LSR to make a one-piece.
This LSR overmoulded mask is different from the traditional silicone mask. With the traditional silicone mask for industry, the plastic and liquid silicone parts are produced separately, then assembled by hand. This can increase labour and time costs, because the assembly is so time-consuming.
LSR overmolding is a process where a liquid silicone rubber (LSR) material is added to a hard plastic surface (e.g. PC, PP, PA or PPSU). This process is commonly used in medical respiratory masks to attach soft silicone to a rigid support frame, providing a comfortable fit and structural support.
Overview of the production process：
1.Plastic substrate injection molding
A common plastic injection molding machine is used to produce the mask body in PC/PPSU/PP material.
2.Positioning and clamping of the substrate in the mold (secondary mold)
The rigid mask substrate is clamped into the special inserts of the LSR mold to ensure precise positioning.
3.Liquid Silicone Injection Molding (Overmolding)
Using the LSR injection molding machine, the A/B component liquid silicone is mixed and injected into the mold cavity, and the overmolding is accomplished through a cold runner needle valve system.
4.Thermal Cure Molding
Rapid curing at a mold temperature of 150-180°C (molding cycle time approx. 30-90 seconds) ensures that the silicone layer is firmly bonded to the plastic structure.
5.Automatic mold release
Automatic mold release by air blowing system or robotic arm improves efficiency and avoids manual contact.
6.Inspection and Packaging
Check the position of the overmolded rubber for completeness, firmness and no air bubbles.
We create high-performance, precision-molded solutions using advanced LSR overmolding technology. As a complete LSR injection moulding solution provider, we make sure every product meets strict industrial standards. This means it is strong, comfortable to use and cost-effective, and it will also help you to work more efficiently.
