Urethane Casting Products for the Marine Industry

Urethane Casting Products for the Marine Industry

Urethane Casting products offer a unique solution in the Marine Industry where specific environmental stress factors place high demands on maintenance and repair parts.

Durability and Cost-effectiveness

In a fast-paced industry where vessels need to be at optimum operating hours, Omarian Rubber Industries has innovative products for providing sustainable solutions that are corrosion resistant and industry effective.

Omarian Rubber Industries has a wealth of experience in the marine industry, and the capacity to manufacture quality custom molded Urethane products.

Marine Industry applications include:

●      Custom Urethane Liners

Custom Urethane Liners are designed to solve wear problems to protect equipment from wear caused by movement. Like other urethane products, these liners help prevent downtime and maintenance and offer long-lasting protection in a corrosive marine environment.

●      Flexibility

Manufactured to withstand seawater and the stress and wear of everyday components like pipeline rollers and tension pads are suitable applications for Urethane Castings. Stress on parts can lead to breaks or damage, and consequently loss of operating hours and revenue. The durability of custom casted urethane can save money and time with the ability to endure more stress than materials like metallic casings.

●      Versatility

Custom Urethane Liners can be used for a wide variety of parts – seals, chafing gears, pipe spacers, rollers, pads, bushings, rings, nozzles, etc.  –the solution is castable.

●      Durability

Urethane casted components hold up well in high corrosive environments like seawater, it withstands vibration and mechanical chafing well, and it is heat resistant. These capabilities make it well suited for marine environments.

Unique Design

To make a urethane casting, a silicone elastomer mold is made, which is injected with urethane and additive resins. The product is cheaper and faster to manufacture and custom-designed to exactly match your product dimensions and specifications.

Urethane castings are used for short-run and low to medium production as the silicon mold itself wears quickly.

●      Master Pattern

A master pattern is drawn up in CAD model of the part needed. Custom drawings offer the ability to manufacture a custom-made unit. Subsequently, the master pattern is utilized to make a 3D print or a CNC model of the required part.

●      Making the Mold

  • Problematic features of certain components that will affect the casting quality, like required holes for fastenings, deep and narrow holes, internal cavities, and channels, can be left out and added after the casting has been made to ensure quality.
  • Silicon molds are easy to manipulate and remove once the casting is set. Pliability eliminates the need for draft angles as needed when utilizing injection molding.

In a marine environment like the OIl and Gas industry Urethane casted parts offers specific advantages t with a range of products that are:

  • Abrasion-resistant
  • Impact-resistant
  • Withstand hardness tests for most applications
  • Tensile Strength up to 14.000 psi
  • Flexural Strength, especially in thin cross-sections

Urethane Casted parts offer the following advantages over other materials:

  • Low Capital Investment – Because the manufacturing process is simplified, substantial cost savings can be made.
  • Short production runs – A component can be casted in a matter of days as opposed to several weeks if different materials and methods are used.
  • Simple Manufacturing Process – It only involves making the pattern, the mold, then pouring the resin.
  • Varied ranges of Toughness and Flexibility – Depending on the desired hardness or flexibility of a component, the composite of resins can be adjusted to match specifications

Machines running in the  Marine Industry benefit from the following applications:

  • Compression Molded Urethane parts like diaphragms used in pumps
  • High impingement resistance, shock absorption, and fatigue resistance parts like pulleys and guide rollers
  • Power Plant and Engine room ready parts that are shock and vibration resistant and can withstand high temperatures.
  • Dampers and shock absorbers that are used in processing plants on vessels that have prolonged lifecycles due to their corrosion-resistant properties.

 Find functional Urethane Casting parts, offering a quick turnaround time and cost-saving solutions here.

Rubber Products in Different Sizes and Diverse Molding Capabilities

Do you need rubber products in different sizes? Maybe you need a choice of rubber molding methods instead. The Omarain rubber uses injection, compression, and transfer molding to produce molded rubber parts in sizes large and small. We can also help you to choose the best rubber molding process for your application. Whether you need standard or custom molded rubber products, contact us for value-added manufacturing that includes design assistance, rapid prototyping, process selection, and more.

Molded Rubber Parts in a Range of Sizes

Does your company buy custom molded rubber parts in a range of sizes? Instead of sourcing them from multiple vendors, you can simplify your procurement activities and order everything from us. In the transportation industry, for example, manufacturers ask us for molded rubber parts that range in size from large railcar suspension components to small valve body seals. They need rubber-to-metal bonded assemblies, too. In the power generation industry, customers ask us to supply them with everything from large insulators for power transformers to small rubber grommets.

For these and many other types of molded parts, The Omarain Rubber provides one-stop shopping. Our recent technology investments underscore our commitment to meeting all of your rubber molding needs. Earlier this year, we invested in a new DESMA 968.400 Benchmark (S2) injection molding machine for rubber parts. This new equipment complements our injection, compression, and transfer molding capabilities for smaller molded rubber components such as grommets, seals, and O-rings. To provide our customers with additional value, we’ve also added new laser marking capabilities.

Rubber Molding Capabilities and Process Selection

Whether you’re a designer, an engineer, or an industrial buyer, The Omarain Rubber can recommend the right rubber molding method for your application. Many customers are familiar with rubber injection molding, but transfer molding or compression molding could be a better choice for what you need. By learning how each process works and understanding the advantages and tradeoffs, you can make an informed decision that covers considerations such as part volumes and per-part costs, tooling costs and turnaround times, part tolerances and complexity, and available rubber materials.

For example, rubber injection molding is usually the right choice for high volumes of parts that require medium-to-high levels of precision. If you need tight control of dimensional tolerances, then transfer molding may be a fit. For flashless molding, both injection molding and transfer molding are options. For high value materials, The Omarain Rubber can incorporate wasteless molding that combines the speed and precision of transfer and injection molding with the low material waste of compression molding. Typically, compression molding is used for large parts and low volumes. For each of these molding methods, Omarain Rubber’s ability to provide you with a cost-effective mold frame means that you can use the same rubber molding method for both rapid prototyping and parts production.

The Molded Rubber Products That You Need

Do you need molded rubber products in different sizes that are produced with different molding methods? You can reduce your vendor list and select the right rubber molding process by partnering with us. Before starting your next project, contact us: Omarain Rubber Industries LLC.

RUBBER PRODUCT DESIGN GUIDELINES

INTRODUCTION

Rubber molding processes, such as extrusions, compression molding, or injection molding, take liquid raw rubber into a mold where the rubber is then cured into the mold shape by heat and pressure. As such, the mold cavity is cut to represent the desired geometry of the molded rubber product. Products such as o-rings, seals, grips, caps, covers, hoses, gaskets, buttons, handles, knobs, rollers, bumpers, hydraulic and pneumatic components are usually all made from rubber molding processes. Most 2-dimensional shapes with specified depths can also be made.

Rubber Product Design - Lamps

Because rubber can be molded into so many different shapes, it can be easy to forget that the manufacturing process does prescribe some limitations to how the final product will look. Due to rubber’s viscoelastic nature and the established molding techniques, the rubber product should be designed with the manufacturing process in mind.

Manufacturing artifacts such as parting lines, sprue marks, or ejector pin marks may appear on the surface of the finished product depending on the molding process. The part geometry may also affect the product quality. Please read on to learn more about design engineer guidelines for molded rubber products.

PRODUCT DESIGN GUIDELINES

1. GENERAL GEOMETRY GUIDELINES

The simpler the geometry of the product, the more cost effective and tolerance friendly it is to produce.

  • If possible, always aim to keep the part symmetrical.
  • Avoid designing overhangs.
  • Avoid designing deep undercuts.
  • Avoid very sharp corner requirements.
  • Critical features should not be spread across separate molds.

2. SURFACE FINISH CONSIDERATIONS

Consider the appearance requirements of your product, and consult with your rubber molding manufacturer to make sure certain manufacturing marks will not appear on surfaces where they would be undesired.

Draft Lines

Where the mold plates come together, there will be parting lines on the product.

Sprue Marks

Where the injector sprue meets the mold cavity, there will be sprue marks on the product.

Ejector Pin Marks

Where the ejector pins will make contact with the rubber to eject the part from the mold cavity, there will be ejector pin marks.

3. DRAFT ANGLES

In order to facilitate release of the rubber product from the mold, draft angles may be required depending on the product’s material hardness. Very soft rubbers may have difficulty releasing from the mold without damage.

4. WALL THICKNESS

Try to keep wall thickness uniform to prevent uneven cooling during the molding process. Uneven cooling rates may cause some areas of the product to shrink or dip.

SUMMARY

In general, the simpler the geometry and more symmetrical the part, the easier it will be to produce. Manufacturing marks may appear on some surfaces, so if surface finish is a concern, the requirements should be stated on the print. Some draft angles may be added in order to release the part from the mold if the rubber material chosen is too soft. Wall thickness should be kept uniform to avoid shrinking and dipping.

Keep in mind that complex geometries may require additional post-molding processing, such as trimming, hollowing, deburring, and other finishing processes. These processes may increase the part cost, and due to the variability of the process may lead to greater part rejections. As such, designing a simpler part should always be the end goal in your rubber molded product for maximum cost savings, quality, and reproducibility.