Rapid Prototyping

Frankson specializes in the rapid production of prototypes that are higher in quality yet lower in cost. We are able to do this because of the wide range of technologies at our disposal and our continual research in the field. When there’s a new innovation we can put to work for our customers, we makes sure to incorporate into our services. That makes Frankson your one-stop shop for every prototyping need you have today – and will have in the future.

Additionally, when required, we can provide low-volume manufacturing (even with up to hundreds of thousands of parts). Our diverse services include CNC machining, plastic/rubber injection molding, metal 3D printing, SLA and SLS.

These services are especially suited to customers who produce prototypes for engineering and sales models – as they make for a smart way to test form, fit and function.

New Product Development

Design For Manufacturability

Frankson remains fully aware of the intricacies of developing custom rubber parts that must perform under extreme conditions.

From the moment we begin working with a customer during the quoting stage, we evaluate the part print with the design for manufacturability – as well as assess what the long-term performance of the part will equate to. Frankson’s extensive teams of engineers and chemists review initial RFQs and part prints in order to offer ways that we might improve the rubber formula and part configuration. This allows us to pinpoint efficiencies in production and assembly before the actual project begins.

We offer this kind of dedication because we think of ourselves as your partner in productivity – and success. We want our customers to not only meet, but to exceed their objectives and projections. As you share goals for your new product, we will advise you as to the best material and molding processes for the application, which will include balancing costs and quality control along with performance requirements and expectations.

Frankson can develop prototypes for both the elastomer compound and the part in small quantities according to your testing needs and purposes. We can also arrange for production ramp-up and inventory control – whatever will best suit your new product launch timetable and sales volume projections.

Molded Rubber Engineering Services

Direct Access To Expertise

Frankson offers an open door policy in regard to accessing our chemists and engineers. This provides you and your teams with ready access to our experts in custom rubber compounding and molding. Our engineers are available every step of the way – from concept to testing to production and, of course, quality assurance.

Molded Rubber Engineering Services

• Part design and development assistance
• Feasibility review
• Cost-effectiveness studies
• Custom rubber material R&D
• ASTM material testing
• Tool and mold design
• Performance testing
• Process mapping
• Production monitoring and testing

Custom Rubber Compounding

500+ Unique Formulations – And Counting

Custom rubber compounding is one of Frankson’s specialties. We mix our materials in-house, which gives us complete control in regard to formula and flexibility – allowing us to meet any and every customer requirement. What’s more, we have our own in-house laboratory for material R&D and mixing capabilities. We have developed a library of more than 500 proprietary elastomer formulas (each prepared for a specific application).

Our chemists draw on this experience when helping customers select the material that will best suit their part and its eventual operating environment. We have had extensive involvement with natural, synthetic and high performance compounds – all of which encompass over 350 different raw materials and over 80 different organic elastomers. This allows Frankson to quickly develop a custom formulation as well as offer material sampling for test purposes, which help ensure that the compound and the part will perform as dictated.

Unlike plastic materials (which computers can model to predict performance), rubber can prove difficult to model – yet remains essential for certain applications that require flexibility and durability. Because of this, Frankson focuses on custom rubber compounding so that we can provide expert analysis for our clients (from the early conceptual stages all the way through to the end product).

Compounding Capabilities

• In-house R&D
• Material selection and sourcing
• Mixing facilities
• Mills and performing equipment
• Material quality control
• 100% traceability of materials

Rubber Prototyping

Right From The Start

Frankson diligently works as a collaborative partner with our clients to develop rubber prototypes and test performance as needed. Rubber prototyping of custom elastomer compounds as well as rubber tooling for parts is essential for new product development. This ensures high performance once production begins.

Rubber Prototyping Services

• Manufacturing feasibility review
• Material development
• Design and prototype of tooling
• Sampling
• First Article Report
• Shipping
• Refinements to parts and/or materials

Rubber Tooling

Custom Built For Your Application

Frankson designs custom rubber tooling (also known as molds) for all of the complex rubber parts we produce. A specialized tool builder builds the tool, which consists of steel plates crafted for precision molding. We can also work with a client’s existing tool (depending on its condition) through our tool transfer program.

Custom Rubber Molding For Difficult To Mold Parts

Frankson specializes in custom rubber molding for the most complex parts. Our engineering team works with each of our clients in order to recommend the best molding process for the part – compression molding, transfer molding or liquid injection molding. We also provide insert molding and over-molding of rubber bonded to metal, plastics and other substrates. The process selected depends on the characteristics and cost of the material to be molded, the configuration of the part and the projected annual production volume.

Rubber molding works by adding precise amounts of heat and pressure to set the part. Once a rubber part is cured, the rubber will have gone through a chemical change. The chemical crosslinking that takes place gives the rubber the ability to flex yet still retain its original shape, which is one of the key advantages of thermoset elastomers for certain applications. This includes hearing aids, miniature pneumatics and even automotive parts that must tolerate temperature variations and/or contact with fluids.

Rubber Advantages

• Durability
• Abrasion resistance
• Environmental resistance
• Ability to pigment
• Accepts bonding agents
• Flexible

Rubber Compression Molding

Rubber Compression Molding Process

Frankson engineers consult with each of our clients to recommend the optimal molding process for the proposed application.

Compression molding involves pre-forming uncured rubber into a specified shape and weight that is put into a mold cavity. After the mold is closed, two plates put pressure on the elastomer, which then fills the cavity. The elastomer is maintained under pressure and heated until the rubber is cured – allowing the part to maintain its shape. Compression molding can be used for different production volumes and applications, which include precision parts. Compression molding also can be used for insert molding and over-molding.

Rubber Transfer Molding

Rubber Transfer Molding Process

Frankson engineers always consult with each of our clients in order to recommend the best molding process for the necessary application.

Transfer molding begins with pre-formed, uncured rubber that is placed into the transfer pot of a closed molding system. The ram/plunger then distributes the rubber into the cavities to be shaped into the part, which is then cured by the application of pressure and heat for a specified time period. Transfer molding can be used for highly complex part geometries and precision applications – as well as over-molding. The process is suitable for molding parts with traditional organic black rubber (including pigmented materials).

Liquid Silicone Rubber Injection

Liquid Silicone Rubber Injection Molding Process

The liquid silicone rubber injection molding process delivers two-part liquid silicone directly into a mixer, which is then injected into the mold cavities through a runner and gate system. The silicone is then held under pressure and heated until it is cured. Silicone rubber is the optimal material for liquid injection molding because it is able to produce precision parts as well as complex over-molded assemblies. The process is also suitable for adding pigment for production of colored components.

Plastic Injection Molding

Plastic Injection Molding Process

Plastic injection molding involves melting granular plastic pellets into a liquid form and then compressing this liquid into the empty cavity of a mold tool. The plastic will retain the shape of the mold as well as the surface texture of the walls of the cavity. After an optimized injection and cooling phase, the now solidified plastic part is ejected and the molding cycle is repeated. This molding cycle can take from as little as a few seconds to several minutes (depending upon part size, molding resin and part design).

Advantages of Plastic Injection Molding

• We have more than 40 different types of plastic that are available for you to choose from for a wide range of mechanical and cosmetic properties.
• Plastic injection molding makes more economic sense for larger volumes. For smaller volumes we recommend other services, which include CNC machining, vacuum casting or 3D printing – depending on your project’s specific needs.
• Hundreds of thousands of moldings can be produced from a single mold.
• Your part can have feature surface quality finishes in a wide range of polishes and textures.
• Overmolding is available to combine different types of plastic into one piece.
• This is ideal for lightweight parts that are immune to corrosion.

Rubber to Substrate Bonding

Rubber to Substrate Bonding

Frankson is experienced with developing the correct compounds for adhesion in high performance applications and with preparing the surface of the insert properly to ensure a strong bond.

We are an industry leader in the bonding of rubber compounds to a variety of substrates – including metal, plastic and ceramics. We use rubber insert molding or rubber overmolding as part of the molding process (depending on the application). Molding rubber over an insert (such as a metal stamping) or overmolding a part with rubber can streamline the final assembly and produce a stronger part with a longer working life for the original equipment manufacturer’s end customer.

Rubber to Metal Bonding Process

Frankson handles the entire process of rubber to metal bonding (AKA insert molding) from developing the rubber compound and adding chemical bonding agents, to procuring and preparing the metal inserts, to bonding and finishing.

For complex inserts, Frankson develops mold designs that will locate, orient and hold the insert in the precise position throughout the molding cycle. When rubber to metal bonding is done correctly, the resulting bond will be physically stronger than the material. This means that the rubber bonded to metal will actually tear before the bond fails. This makes insert molding an excellent option for adding strength and stability to rubber bonded to metal.

Chemical Bonding

Our engineers and chemists work to improve the quality of the bond through various steps, including (but not limited to):
• Degreasing and cleaning
• Abrading
• Chemical etching
• Applying a bonding agent or adhesive

Applications

• Hydraulics and pneumatics
• Automotive and heavy truck
• Medical devices

Bonding Rubber to Plastic and Other Substrates

Rubber to plastic bonding (AKA insert molding) is an intricate process. This is because plastic cannot endure the same temperature and pressure that metals can. However, plastic remains favored as a component since it’s lightweight, less expensive and unbendable, which works well for certain applications.

Frankson can source the proper plastic insert, as required, as well as develop the elastomer and chemical bonding compound needed for maximum performance of the part. Often, over-molding is used to completely cover the plastic part and serve as a barrier to operating environment hazards.

Chemical Bonding

Our engineers and chemists continually work to improve the quality of the bond through various steps, including:
• Degreasing and cleaning
• Abrading
• Chemical etching
• Applying a bonding agent or adhesive

Clean Room Molding

ISO Class 8 Clean Room Molding

Frankson specializes in medical silicone injection molding, which results in custom-molded, precision silicone components for implantable and disposable medical devices.

Our engineers work with each of our clients to determine the best molding process and manufacturing controls for the application (keeping in mind the client’s material preferences and plans for manufacturing and assembly).

We employ the most advanced technologies in silicone mixing and molding operations – including computer-operated and controlled production, custom automated assembly and automated measuring machinery – to ensure consistent quality.

Quality Assurance

Quality Assurance for Compounding and Molding

At Frankson, following ISO and other international quality standards and industry practices is only part of the process. We continually offer our diverse knowledge base and highest quality assurances to all of our clients.

We build quality assurance into every step of rubber compounding and rubber molding – from material sourcing and testing, to production and final inspection. Frankson works with clients in numerous industries – each of which has strict quality standards. Examples include the medical industry and food/water/dairy handler industries.

Compounding Quality Assurance

• ASTM testing on materials
• FDA and NSF/ANSI 61 compliant materials
• Material sourcing from proven suppliers
• Material batch testing from in-house and independent labs
• 100% material tracking

Molding Quality Assurance

• ISO 9001:2008
• ISO 16949:2008
• ISO 14000:2008
• APQP
• PPAP
• FMEA
• Manufacturing feasibility review
• Performance testing
• Inspection
• 100% product tracking

Secondary Operations

Rubber Molding Secondary Operations Move Your Product to Market

Frankson happily provides a full range of rubber molding secondary operations and value-added services to take your part from the final stage of the molding production line to anywhere in the world you assemble your product.

Our secondary operations ensure that your part meets the strictest standards and specifications. Our value-added services can even help speed final assembly. Examples of these services include light assembly and component sourcing for kits and inventory management.

Secondary Operations

• Cryogenic deflashing
• Spin trimming
• Custom manual finishing
• Post cure, coating, grinding
• Chlorination

Value-Added Services

• ASTM testing
• Light assembly
• Inspection
• Kitting
• Packaging
• Inventory management

On Time Production

Frankson offers masterful project management from our technical experts so that your part production will meet your scheduling needs. We develop a Gantt chart that we review with customers to ensure that all of the steps in product development are understood in advance – and then ensure these steps are completed accurately and on time. We can produce flexible volumes for product ramp-up as well as seasonal variations in demand. We can even assist with inventory control by stocking parts.