Trelleborg: Accelerating Product Development and Small Batch Production of LSR Parts

Trelleborg Sealing Solutions supports 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 unique iCastTM LSR process offers manufacturers a cost-effective way to develop product variants or try out different design concepts before investing in mass production tools. In addition, the process allows the start of pre-series and series production with small batches, to bridge the gap between low and high volume production.

Felix Schädler, Project Manager Innovation & Technology at Trelleborg Sealing Solutions, says: “iCast™ LSR is an adaptable five-step modular process that uses digitization and new manufacturing techniques. It can drastically reduce the time from design to production of prototypes from several weeks to a few days for the average part. This helps manufacturers respond to the pressures of rapidly changing markets that require faster introductions, improvements, and new product advancements. »

The Trelleborg iCastTM LSR process begins with the submission of 3D part data and order details. A feasibility study based on artificial intelligence (AI) is triggered to confirm if the iCastTM LSR process is suitable for the production of the part. After the feasibility study is completed, the part design is analyzed and the individual digital mold layout is created based on the 3D data. If necessary, this undergoes mold flow simulation. In a virtual environment, this process identifies the optimal production process for using additive manufacturing (AM) technologies to achieve the highest possible quality.

With iCastTM LSR technology, rapid, multiple component design iterations can be achieved in a standard, industrial-grade platinum-cured two-component LSR. These demonstrate the properties and quality levels of high volume injection molded parts. Currently suitable for production of 1 to 2,500 parts, Trelleborg’s iCast™ manufacturing process can be used to produce a wide range of 2D and 3D LSR components, including O-rings, profile seals, diaphragms and castings tailored.

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Gary C. Lisi