Sponge Rubber Conversion Tools & Techniques
Rubber Conversion Specialists
Rubber compounds are typically available in a wide range of formats, shapes and sizes. Here at The Rubber Company we specialise in converting rubber into end products in order to suit our customer’s needs. Utilising a variety of rubber conversion tools and techniques we can convert rubber into high quality, bespoke products. We understand that no two requirements will ever be the same, so we tailor each project to suit your requirements. We can work with you every step of the way. Our dedicated team can assist in everything from providing useful technical and material advice during the design process through to manufacturing material samples prior to bulk production.
Benefits Of Rubber Conversion
- Bespoke production to your exact requirements
- Reduces material costs
- Suitable for simple & detailed designs
- Suitable for small to large production runs
- Wide selection of tools & techniques available
Common Conversion Techniques
We have listed a selection below of our most commonly used rubber conversion tools and techniques. These techniques can be utilised on a variety of material compounds in order to achieve a range of formats. It is worth noting, that our conversion capabilities are always expanding and our processes are not limited to this list.
Slitting
Slitting machines are ideal for horizontally cutting sheets of sponge rubber from large blocks of raw material. The roller ensures that consistent pressure is applied in order to achieve tight tolerances regardless of the material used. Slitting is widely considered the most popular method for converting blocks of rubber in sheeting for use end use or for further converting.
Bandsaw
Bandsaws are utilised to vertically cut basic shapes and designs from rubber sheets or blocks. The main advantage of bandsaws is the tools relatively quick set up and process time. This can help to reduce lead times on larger orders. Bandsaws can also achieve consistently clean cuts.
Oscillating Blade
Oscillating bales, also known as CNC cutting machines are essentially computer-controlled bandsaws with a much smaller blade. Much like bandsaws CNC machines cut vertically, however the set-up is different. The main benefit in using oscillating blades is that the blade is controlled by a computer which enables it to cut intricate shapes quickly and repeatedly.
Grinder
Grinder machines are typically used to grind down sponge and foam rubber from a sheet or black into a cylindrical shape. As the grinder is able to apply consistent pressure we can achieve highly accurate measurements, which are maintained across the length of the shape.
Boring
Boring tools are used create inner diameters or “cut-outs” in sponge rubber. The tool is incredibly easy to set up and use, which makes it easy to create multiple cuts. The blade section can be swapped out in order to cut a variety of diameters.
Die Stamping
Die stamping machines utilise a hydraulic press in order to accurately cut out 3D shapes. Once set up the machine can consistently cut shapes to the same size. Die stamping is typically used for medium to large production runs as it is able to cut
multiple shapes at a time.
Mangle & Nip Rollers
Nip rollers are typically used to provide pressure in order to improve the adhesion of self-adhesive backing to sponge and foam sheets. The rollers enable us to feed the material through to ensure that the pressure is applied to the whole sheet. This results in an adhesive backing that is able to withstand regular movement and impact.
Sewing
We regularly utilise sewing machines to produce out stitched bellows. Sewing machines are ideal for joining two or more materials together, as long as the application doesn’t require a waterproof barrier. Using sewing machines, we can easily create any length, width or shape required. This technique is also useful for creating material samples prior to bulk production.
Laser Cutting
Laser cutting machines are ideal for cutting highly intricate shapes and designs. We can also use laser machines to add bespoke details and designs to materials. As laser cutting machines are computer controlled it is possible to consistently replicate detailed designs.
Cooking
Cooking machines are used to achieve high temperatures in order to improve the strength of joins between multiple cut pieces. The machine is very easy to set up with cooking times varying depending on the material and number of pieces used.
Gluing & Welding
Utilising gluing and welding enables us to adapt our standard profiles and sheet sizes to fit our customers specific application. This is typically used to join two profiles together in order to fit in a corner or around a particular radius. The set up and process is very quick, which makes this method ideal for small to medium production runs.
