Clifton Rubber Capability FAQs

rRubber moulding is a process of transforming uncured malleable rubber into a usable elastic product by transferring, compressing, or injecting raw rubber material into the shape of a mould cavity.  The heat and pressure induced during the moulding process cause the polymer chains in the material to crosslink and form a rigid elastic structure in the shape of the cavity.

Moulded rubber products are made by transferring, compressing or injecting raw rubber materials into the shape of a mould cavity. Rubber mouldings can be made from any commercially available rubber and in a wide spectrum of colours and hardness’s. Common materials include Natural Rubber, Neoprene, Silicone EPDM and others.

MThe most common methods for rubber moulding are injection, compression, and transfer.  For more details of how each of these processes work, please read here

We manufacture custom rubber mouldings so there is no limit to the possibility of form, size or shape of a moulding.  We make parts from all commercially available rubber materials in various hardness, colour and surface finish.  We can work to customer drawings and will help to ensure your custom rubber part is Designed for Manufacture.

Rubber moulded products are used in almost every industry. Examples of these industries include medicine and healthcare, electronics, aerospace, automotive manufacturing, offshore, transportation, sports and leisure, agriculture, recycling and many more.

Common materials we process include: Natural Rubber, Neoprene, Nitrile (NBR), EPDM, Silicone, Viton, SBR, Hypalon

We can carry out a range of tests on product and material quality and our experts can advise on the best inspection methods for your project.  Our ISO9001 quality management system is at the heart of our processes and products are regularly quality inspected during the manufacturing process to ensure high customer satisfaction.

Rubber moulding can be used for a wide range of components in various shapes and sizes and in various quantities.   Mould tools are designed around the typical batch quantity so they can incorporate a single cavity to produce one off trial samples, or we can produce large multi cavity tools for high volume production runs.

Injection moulding is where rubber is continuously fed into a screw and then injected by a ram into a closed mould cavity.  Injection moulding is generally better suited to high volume production of smaller complex parts with a thin wall.  Compression moulding is the insertion of pre-formed rubber blank material into an open mould cavity which is then closed under pressure to form a shape.  Compression moulding is better suited to lower volume simple parts which can be quite large in size. To find out more about the advantages and disadvantages of each method read our ‘What is Rubber Moulding’ page.

It can definitely be used for both.  We manufacture a range of standard components available in our products section for a wide range of industries.  In addition, we carry out many custom projects for customers to match their requirements.  (link to page)

If we have an existing mould our average lead time is around 2-4 weeks depending on required quantity and material specifications.  New moulds are manufactured by our in-house toolmakers and have a typical lead time of 6-8 weeks for tooling and first off samples.

Temperature and pressure are the two critical factors in the mould curing of a rubber product.  If temperature is not controlled precisely then the rubber moulded part may not reach its designed elasticity resulting in products which do not perform as intended.

No – we can create a mould tool for any required shape.

Yes – you can have a range of finishes – rough, smooth, patterned, polished and many more.

Polyurethanes are a versatile material that are used in a wide variety of applications. We produce cast polyurethane elastomer products which are used in all manner of consumer and industrial products such as PU screening stars, PU bellows, PU dunnage, PU rollers etc.  Polyurethane foams make up the largest segment of the PU market and these materials are used primarily for insulation boards, mattresses and shoe cushioning products.  Polyurethane adhesives, coatings and paints are used in liquid form in products which cover, seal or adhere to another material or structure.

Whilst polyurethane systems are neither the same as rubber nor plastic in chemical structure, polyurethane does fall into the same high-level category of synthetic polymer materials.  Generally, plastics and rubbers are differentiated by their elasticity, where rubber is an elastic material that will return to its original shape when deformed and plastic is an inelastic material that will permanently deform when stretched or impacted.

Clifton Rubber’s polyurethane casting systems are thermosetting elastomers with permanently linked polymer chains that have elastic properties very similar to rubber.

Certain polyurethane systems will suffer from hysteresis if subject to high friction applications such as fast-moving PU wheels and tyres.  Polyurethane can also be affected by ozone and weathering so may not endure as long in certain external applications as rubber alternatives.

Yes – we work with customers to manufacture products that meet their exact requirements including custom or bespoke polyurethane projects.

Polyurethane is durable and can be 100% waterproof.

Polyurethane has excellent abrasion and dynamic load resistance and is a castable liquid that can be moulded into various shapes. This makes PU an excellent material in many applications.  We have produced thousands of custom products to match customer requirements with recent examples including PU wheels, buffers, coatings, rings, rods and sheets.

Yes – we can make it in a range of colours to suit your need.  Polyurethane colours we have processed include grey, red, blue, yellow, orange, green, white and black.

Yes it can – although it depends on the application you are using it for. Contact one of our technical team to discuss your requirement.

Polyurethane elastomers can be recycled in one of two ways: either mechanically, in which it’s reused in its polymer form, or chemically, in which it’s broken back down into its chemical components. Common uses for recycled polyurethane include carpet padding, boards and mouldings that can be used in soundproofing and flooring, and even as raw material for new polyurethanes.

We supply polyurethane products to a range of industries across the globe – including agriculture, waste & recycling, automotive, transport, food & drink, manufacturing, offshore and construction.

PU Mouldings are extremely versatile materials that can yield different properties dependant on the system used, either rigid or flexible, hard or soft, resilient, durable and hard wearing.  PU’s withstand formidable levels of corrosiveness, pressure, abrasion, impact & heat.

We offer custom production capabilities and solutions to suit a customer’s needs and also offer a range of standards polyurethane components available to buy directly.

This depends very much on the product and the customer requirements which is why we will work with you every step of the way to ensure your project is delivered on time and on budget.

There is no minimum order quantity – we produce one off prototype products through to high volume production runs.

Absolutely.  Our commonly specified colours being: Black, Red, Yellow, Green, Orange and Blue and we offer a range of textured finishes.

We cover products in a range of thicknesses depending on the end application of the rubber roller. For example, natural rubber has strong physical characteristics such as high abrasion and tear resistance, good mechanical grip, and excellent flexibility.  It is therefore suitable for most industrial applications.

Rubber Coverings are used in a wide range of applications. Typical projects carried out by Clifton Rubber include:

• Conveyor Drive and Idlers
• Print
• Transfer
• Materials Handling
• Agriculture
• Laminating
• Squeegee
• Solid Tyre Wheels
• Food Processing

To find out all about the rubber covering process read more HERE 

For our customer’s benefit we can offer rubber rollers manufactured from common commercially available rubber and in a wide spectrum of colours and hardness.

We stock materials formulated for high and low temperature, food quality (FDA approved), anti-static and flame retardant applications.

Our stock materials include:

• Ebonite
• SBR
• Natural Rubber (NR)
• Neoprene
• Nitrile
• EPDM
• Hypalon
• Silicone
• Polyurethane

Common extruded rubber products are rubber bushings, rubber cords, door seals, trims, tubes, hoses, pipes, gaskets, O-rings, and weatherstrips.

The most common material for rubber extrusion is EPDM which is a synthetic rubber compound with excellent properties suitable for most extrusion profile applications.

• ‘D’ Sections
• ‘E’ Sections
• ‘L’ Sections
• ‘P’ Sections
• ‘U’ Channels
• Box Sections
• Trapeziums
• Lip Seals
• Rubber Tubes
• Rubber Cords
• Rubber Piping
• Rubber Door Seals

A typical product will take about 4 working weeks to complete from start to finish.

Yes – we can manufacture extrusions for all industries and already supply to a wide cross section of industries.

Rubber sheet conversion is the process of converting rubber sheeting to produce bespoke end products for many different applications to suit our customer’s needs.

Our typical products include rubber gaskets, rubber seals and various other non-metallic washers, gaskets, seals, insulations and sheeting.

We can manufacture from a range of materials including:

• Natural Rubber (NR)
• Styrene-butadiene rubber (SBR)
• EPRM
• Neoprene
• Hypalon
• Nitrile (NBR)
• Fluorocarbon Rubbers (FKM/FPM)
• Silicone

We typically turn around a product within 3 to 4 weeks from placement of the order.

Yes we can.  Our rubber gaskets are manufactured to the customer’s design and can be produced in all shapes and sizes to meet even the most obscure requirements.

Get in touch with our Friendly Technical Sales Team who will be with you every step of the way.

The primary differences between these rubber materials is in their chemical resistance and temperature ranges.

VITON is a synthetic rubber and fluoropolymer elastomer. “Fluoropolymer” means this material has high resistance to solvents, acids, and bases. “Elastomer” is a word that is basically interchangeable with “rubber.”

Advantages:

• Withstands high temperatures
• Withstands a wide range of chemicals – oils, gases, silicone fluids and mineral acids
• Good electrical properties and low burning characteristics
• Good in harsh environments – resistant to weather, UV exposure, oxidation, fungus and mould

Disadvantages:

• Expensive
• Poor performance at low temperatures
• Decomposes under excessively high temperatures

EDPM is ethylene-propylene-diene-monomer.  It is a synthetic rubber compound made from the chemicals in its name and is used in many applications.

Advantages:

• Strong resistance to hot and cold temperatures
• Excellent weathering properties – ozone and sunlight resistant
• Excellent tear abrasion
• Lightweight and long lasting
• Water resistant

Disadvantages:

• Poor resistant to petroleum based fuels, most oils, gasoline, kerosene, aromatic and aliphatic hydrocarbons, solvents and acids

NEOPRENE

Neoprene (also polychloroprene) is a family of synthetic rubbers that are produced by polymerization of chloroprene.

Advantages:

• Impermeability
• Elasticity
• Good resistance to water
• High tensile strength properties
• Better flame retardant properties

Disadvantages:

• Higher cost
• Poor resistance to strong oxidising acids, esters, ketone and certain hydrocarbons.

Each of these three materials are considered to be excellent all-purpose fabrics. However, commonly EPDM is an excellent choice for outdoor applications and is a popular choice within the automotive industry. Neoprene is a popular choice for its flame retardant capabilities, oil resistance and overall durability.  Viton has good durability.

To maintain a quality product and service we put quality at the heart of our processes. We work with you every step of the way – from initial consultation, to design, production and delivery.  Our quality management system is therefore certified to ISO9001.

 Precision engineering is a process of designing and manufacturing products with the highest level of accuracy, consistency, and reliability. It involves the use of advanced technologies and techniques to create precise components that meet specific requirements and tolerances. Precision engineering is essential in industries such as aerospace, medical devices, automotive, and electronics where even the slightest deviation can result in significant consequences.

A precision engineer, also known as a precision machinist, is a highly skilled professional who specialises in the production and maintenance of precision components and equipment. Their work involves using advanced machinery and tools to manufacture, assemble, and test intricate parts with extremely tight tolerances and high levels of accuracy.

An example of mechanical precision engineering in rubber moulding is the production of precision mould tools required to manufacture rubber components with intricate geometries, tight tolerances, and complex designs. This can include products such as O-rings, rubber grommets, rubber diaphragms, or custom rubber parts used in industries like automotive, aerospace, electronics, and healthcare. 

Precision engineering is a discipline found in various engineering sectors such as:

• Mechanical engineering: This field is the oldest form of engineering and focuses on the design, manufacture and maintenance of mechanical components and systems with high precision and accuracy. It includes the production of precise machinery, tools, mechanical assemblies and mechanisms. 

• Electrical and electronic engineering: This discipline involves the design, fabrication, and testing of precision electrical and electronic components, devices, and systems. It includes areas such as precision electronics manufacturing, circuit board design, microelectronics, and semiconductor manufacturing.
• Optical engineering: Optical precision engineering deals with the design and fabrication of high-precision optical components, systems, and instruments. This field includes the production of lenses, mirrors, prisms, optical coatings, and the development of precision optical measurement and imaging systems.
• Micro/nano engineering: Micro and nano precision engineering focus on the design, manufacturing, and manipulation of structures and devices at the micro and nanoscale. It involves areas such as microfabrication, nanotechnology, precision micro-machining, and the development of micro/nano devices and systems.

Precision tolerances refer to the allowable variation or deviation from a specified dimension or measurement. Tolerances are established to ensure that manufactured components or parts meet the desired specifications and can function properly within the intended application.

In precision engineering, tighter tolerances indicate a higher degree of precision required. A tight tolerance means that the allowable deviation from the specified dimension is very small, resulting in a more precise and accurate component. On the other hand, looser tolerances allow for greater variation from the specified dimension. At Clifton Rubber we work to general tolerances as defined by ISO 2768-1 but can work to tolerance as specified by our customers (within reason).

While precision engineering brings numerous benefits, it also has some potential disadvantages. Here are a few considerations:

• Cost: Precision engineering often involves sophisticated equipment, tools, and processes, which can be expensive to acquire and maintain. The high level of precision required may necessitate the use of specialised materials and manufacturing techniques, increasing production costs. This can make precision-engineered products and components more expensive for consumers.
• Complexity: Achieving high precision can add complexity to the design and manufacturing process. Tight tolerances and stringent quality control requirements may require additional steps and resources. This complexity can increase the risk of errors, delays, and potential difficulties in scaling up production.
• Sensitivity to Environmental Factors: Precision-engineered components and systems may be sensitive to environmental conditions such as temperature, humidity, and vibrations. Even small variations in these factors can affect the performance and accuracy of precision-engineered products. This may require additional measures or protective measures to ensure optimal functioning in different environments.
• Skill and Expertise Requirements: Precision engineering demands specialised knowledge, skills, and expertise. Engineers and technicians working in this field need to be highly trained and experienced to ensure accurate and reliable results. The complexity of precision engineering processes may require ongoing training and development to stay updated with the latest techniques and technologies.
• Time-Consuming: Achieving high precision often requires careful planning, meticulous execution, and thorough quality control. The time required to achieve precise results can be longer compared to less precise manufacturing methods. This can impact production timelines and may not be suitable for applications with tight deadlines.
• Material Limitations: Precision engineering may have limitations when it comes to certain materials. Some materials may be more challenging to work with at high precision, or their properties may limit the achievable precision. This can restrict the choice of materials for specific applications.
• Maintenance and Calibration: Precision equipment and instruments require regular maintenance and calibration to maintain their accuracy and performance. This ongoing maintenance can add to the operational costs and time requirements.

It is important to note that these disadvantages should be considered in relation to the specific requirements and applications of precision engineering. While there may be challenges, precision engineering remains a crucial field that enables the development of advanced technologies, high-quality products, and innovative solutions to complex problems.

Yes – we can undertake just about any project a customer has in mind. Our precision mechanical engineers and toolmakers have the expertise and resources to address your specific requirements.

We undertake projects across a wide range of industries.  More commonly we work in Agriculture, Recycling, Medical, Food & Drink, Construction and Transport.

We are skilled mechanical engineers and toolmakers and our range of equipment allows us to undertake the following processes.

• CNC Turning
• CNC Milling including 4th axis 
• Manual Milling & Turning
• CNC Automated Sawing
• Drilling & Tapping
• Spark Eroding
• Welding & Fabrication
• CAD/CAM
• Precision Inspection & Measuring

Lead times for precision engineered products vary depending on the project.  Factors such as complexity, materials, volumes, size and workload would need to be taken into consideration when confirming lead times. At Clifton Rubber we would try to give an accurate estimation of lead time at the quotation stage and will always work hard to meet our customer’s expectations.

In precision engineering there are generally no minimum order quantities. At Clifton Rubber we can machine one off prototype parts and mould tools through to high volume continuous production runs.