rubber molding

case study
case study
close
case study example
the problem
A global leader in automotive lighting came to PHB with the challenge of creating two castings – one for low beams and one for high beams. Because of the complexity in aligning the fixtures (heat sink pads) for the LEDs, prior designs had only allowed them to have three heat-sink pads per casting. Since both the low beams and high beams required six heat sinks, each headlight required four castings. The problem compounded when the mirror design was required for left or right headlights. With the added expense of creating separate tooling for all of the castings, and the additional time and expense involved in aiming these eight castings, our customer realized it was time for a new solution.
the solution
The challenge in producing the six heatsink pads was to maintain the profile tolerance to the 6 pads to within .4mm to the datum structure. There are 17 individual features at each pad location, or 102 total features per casting that are critical to function. Any missing feature results in a part that our customer cannot fully assemble. PHB utilized the MAGMA process simulation and other camera quality inspection, close tolerance machining, and precision quality control to develop and produce a two-casting headlight assembly for our customer.
  • This field is for validation purposes and should be left unchanged.

Why Choose PHB for Custom Rubber Molding?

  • PHB Molding Division’s large capacity allows us to produce high volume rubber components
  • Our manufacturing process allows us to provide cost-effective low volume production
  • With a range of rubber types and processes, PHB solves problems in Rubber molding globally
PHB Rubber Molding offers you the ability to design and build tooling while assisting with the design of the product. We also provide prototyping, assembly, overmolding, product graphics, custom packaging and shipping. Our rubber molding division runs three shifts of production, including both low volume and high volume jobs. We are able to repair and run older rubber molding tooling as well as provide specific testing and compliance certifications. PHB Injection Molding is ISO 9001-2008 Certified. We utilize Electronic Data Transfer, and JIT production scheduling to meet customer requirements.

Rubber Molding Capabilities

Injection Molding Rubber Products:

  • Viton
  • Nitrile
  • Neoprene
  • Hycar
  • Silicones
  • NR
  • EPDM
  • Custom Blends
  • Viton
  • Nitrile
  • Neoprene
  • Hycar
  • Silicones
  • NR
  • EPDM
  • Custom Blends

PHB Injection Molding Markets Include:

  • Railway
  • Appliance
  • Automotive
  • Electronic
  • Military
  • Aerospace
  • Medical
  • Safety Applications
  • Transportation
  • Industrial Products
  • Home Products
  • Railway
  • Appliance
  • Automotive
  • Electronic
  • Military
  • Aerospace
  • Medical
  • Safety Appliances
  • Transportation
  • Industrial Products
  • Home Products

Insert Molding

PHB Molding produces overmolded products in both Rubber and Plastic. The following is a list of examples to showcase the spectrum of our injection molding capabilities:

  • Molding Thermo-set rubber over Glass Filled Nylon with a Chemlok Adhesive that will provide both a mechanical and chemical bond between the two parts
  • Overmolding of brass or steel threaded inserts into thermoplastic parts
  • Post Sonic welding threaded inserts
  • Overmolding Thermo-set Rubber on Metal products

Other Services

PHB provides a number of value added services to serve our customers and keep lead times at a minimum. These services include:

  • Custom trimming of rubber products
  • Custom assembly as required for variations of product versions
  • Special labeling and assembly of both Plastic and Rubber products
  • Cryogenic Deflashing of rubber products
  • Creating multi-colored, decorative silkscreen labels and logos
  • Rubber Surface Finishing, Gluing, Cryogenic
  • Special packaging

choose phb for your rubber molding needs today

rubber molding gallery