Compression Molding Services

Frigate employs compression molding to shape thermoplastic and thermosetting materials. This method achieves high dimensional accuracy and consistent mechanical properties.

Get Your Quote Now

Custom Compression Molding Services

Frigate provides custom compression molding services tailored to specific material requirements. This process uses heat and pressure to shape thermosetting and thermoplastic materials into precise components. Accurate molds ensure consistent quality and dimensional accuracy in every part produced. Compression molding allows for complex geometries and efficient material usage, reducing waste. It is suitable for high-volume production and delivers strong mechanical properties.

Achieving Consistent Dimensional Accuracy

Advanced Mold Design

Utilizing sophisticated mold designs minimizes variations and ensures that each part maintains the desired specifications.

Process Monitoring Systems

Implementing real-time monitoring systems helps track process parameters, allowing for immediate adjustments to maintain accuracy.

Material Selection Expertise

Leveraging expertise in material properties ensures the right materials are chosen to reduce inconsistencies in production.

Improving Lead Time and Production Efficiency

Streamlined Workflow Processes

Developing efficient workflows and processes reduces unnecessary steps and improves overall production timelines.

Quick Setup Techniques

Adopting quick setup techniques minimizes downtime between production runs, enhancing responsiveness to customer demands.

Automation Integration

Integrating automation in the molding process boosts speed and efficiency, reducing lead times while maintaining quality.

Strengthening Production Reliability

Efficient Material Usage

Employing advanced material calculation and utilization techniques ensures optimal use, reducing excess waste.

Recycling Strategies

Implementing recycling strategies for leftover materials allows for reprocessing and reduces the overall environmental impact. to analyze casting designs for potential stress points and optimize them for strength and performance. This minimizes the risk of casting defects and ensures parts can withstand intended loads and operating conditions.

Precise Process Controls

Utilizing precise controls in the molding process minimizes scrap rates and ensures that production runs are as resource-efficient as possible.

Compression Molding Materials

Compression molding is an efficient manufacturing process using heat and pressure. This technique shapes materials into complex parts with precise dimensions and properties.

Thermosetting Plastics

Thermosetting plastics, such as epoxy and phenolic resins, are commonly used in compression molding. When heated, these materials undergo a chemical change, resulting in a rigid, durable final product. They provide excellent heat resistance and dimensional stability, making them suitable for applications in the automotive and electrical industries.

Thermoplastic Elastomers (TPE)

Thermoplastic elastomers combine the properties of rubber and plastic. They offer flexibility, elasticity, and chemical resistance. TPEs can be molded and remolded multiple times, making them ideal for applications requiring soft-touch surfaces and high-performance seals.

Polymer Composites

Polymer composites, which consist of a polymer matrix reinforced with fibers, provide enhanced mechanical properties. Materials like glass-reinforced and carbon-reinforced composites are often used. These composites exhibit high strength-to-weight ratios and are suitable for demanding applications in the aerospace and automotive sectors.

Silicone Rubber

Silicone rubber is valued for its flexibility, thermal stability, and chemical resistance. It is widely used in applications requiring high-temperature resistance and is often employed in automotive seals, gaskets, and medical devices. Frigate utilizes silicone rubber to produce components that require precise performance under extreme conditions.

Natural and Synthetic Rubber

Natural and synthetic rubber are utilized for their elasticity and durability. Rubber compression molding is common in producing seals, gaskets, and other flexible components. These materials provide excellent shock absorption and resistance to wear.

Metallic Powders

For compression molding processes, certain applications may require metallic powders, such as aluminum or stainless steel. These powders can be combined with polymers to enhance strength and thermal conductivity, making them suitable for specialized applications in electronics and machinery.

Enhancing Design Flexibility in Compression Molding

Due to process constraints, designing parts with complex geometries in compression molding poses challenges. Mold shape and dimensions must be carefully considered, as undercuts and intricate features complicate manufacturing. Frigate employs advanced mold design techniques to enhance versatility. Utilizing computer-aided design (CAD) software allows for precise simulations that predict performance and ensure specifications are met. Collaborative design processes facilitate adjustments that align with molding capabilities while maintaining functionality and aesthetics.

Compliance for Compression Molding Services

Compliance for Compression Molding at Frigate involves stringent monitoring and control to ensure precise adherence to industry standards. The materials used undergo extensive testing to meet regulatory requirements for performance and safety. Advanced process controls guarantee consistency and reliability in every part. Frigate focuses on precision and accountability throughout all manufacturing stages, ensuring compliance with critical specifications.

ISO 9001:2015 (Cert. No. QMS 12345)

Validates Frigate’s structured approach to quality management, ensuring product consistency and traceability across all production stages.

RoHS (Cert. No. 1234567890)

Compliance with RoHS limits the use of toxic substances like lead, mercury, and cadmium in molded parts.

REACH (Cert. No. REACH-12345-6789)

Confirms that all chemicals used in production are registered, evaluated, and safe, minimizing risks to health and the environment.

FDA 21 CFR Part 820 (Cert. No. FDA-123456)

Ensures Frigate’s molding processes meet FDA guidelines for medical device components, including stringent biocompatibility standards.

UL 94 (Cert. No. UL-123456)

Assures that molded materials meet flammability ratings, preventing fire hazards in electrical and automotive components.

ISO 14001:2015 (Cert. No. EMS 98765)

Ensures Frigate's environmental management system reduces waste, improves resource efficiency, and minimizes ecological impact.

Tolerance for Compression Molding Services

Flash Thickness

±0.001 to ±0.010 inches

Flash tolerance defines the excess material around the molded part. Precision control is critical to ensure minimal waste and defects.

Core Radius

±0.001 to ±0.005 inches

Tolerance for radii in the mold core, critical for parts with curved or contoured surfaces to prevent fitting or functional issues.

Draft Angle

±0.1° to ±0.5°

Controls the angle of the mold cavity’s taper, ensuring smooth ejection and minimal deformation of the part during demolding.

Parting Line Offset

±0.001 to ±0.005 inches

Tolerance for the parting line, ensuring precise alignment between the upper and lower mold halves to maintain overall part integrity.

Gate Location and Size

±0.002 to ±0.010 inches

Precise control over gate placement and size to avoid material flow defects, ensuring optimal mold filling and part quality.

Ejector Pin Mark

±0.001 to ±0.005 inches

Tolerance to ensure minimal surface impact from ejector pin marks, preserving part aesthetics and function.

Vent Size

±0.001 to ±0.005 inches

Control of vent dimensions, ensuring air is efficiently released during molding to prevent defects like air pockets or incomplete filling.

Compression Ratio

±1% to ±5%

Variation in the compression ratio, controlling the material flow into the mold, critical for uniform density and part strength.

Compression Set

±0.005 to ±0.020 inches

Tolerance for material recovery after compression, ensuring the part maintains its shape and performance after molding and cooling.

Mold Temperature

±5°F to ±15°F

Controls temperature fluctuations during the molding process to prevent material shrinkage or warping, ensuring consistent part quality.

Injection Pressure

±50 psi to ±200 psi

Tolerance for pressure applied during molding, ensuring precise material flow and preventing voids, bubbles, or incomplete parts.

Curing Time

±1% to ±3% of total cycle time

Tolerance in curing or curing time variation during the molding process, ensuring parts achieve the desired hardness and material properties.

Shrinkage Rate

±0.5% to ±2%

Controls the shrinkage of the part post-molding, critical for parts requiring tight tolerances and minimal dimensional changes.

Material Density

±1% to ±3%

Tolerance for the density of the molded material, ensuring consistent strength, durability, and material properties for functional parts.

Quality Testing Standards for Compression Molding Services

Volumetric Shrinkage

Precision Volume Measurement

Evaluates the reduction in part volume post-cooling, ensuring dimensional stability and tight tolerance compliance.

Fiber Orientation

X-ray Computed Tomography (CT)

Analyzes fiber alignment in reinforced materials, critical for directional strength and structural integrity.

Void Content

Ultrasonic Testing

Detects and quantifies voids or air pockets within molded parts to prevent structural weaknesses.

Residual Stress Analysis

X-ray Diffraction (XRD)

Measures internal stresses caused by molding to avoid cracking or deformation during service life.

Thermal Conductivity

Laser Flash Analysis (LFA)

Determines the heat transfer rate through the material, essential for thermal management applications.

Elastic Modulus

Dynamic Mechanical Analysis (DMA)

Evaluates the stiffness and elastic behavior of the molded part under applied loads.

Dielectric Properties

Dielectric Spectroscopy

Measures the material's electrical insulation properties across a range of frequencies.

Gas Permeability

Permeability Test Chamber

Assesses the material's resistance to gas diffusion, crucial for airtight applications.

Creep Resistance

Creep Testing Rig

Evaluates the material's deformation over time under constant load and temperature.

Thermal Expansion Coefficient

Thermomechanical Analysis (TMA)

Determines how the material's dimensions change with temperature variations, ensuring thermal stability.

Mold Residue Analysis

Spectroscopy or Chromatography

Identifies residue left in the mold after molding, ensuring proper cleaning and minimizing contamination risks.

Glass Transition Temperature

Differential Scanning Calorimetry (DSC)

Identifies the temperature where the material transitions from rigid to a rubbery state, critical for performance.

Fatigue Strength

Rotating Beam Fatigue Test

Assesses the ability of the part to withstand cyclic loading without failure over time.

Microstructural Analysis

Scanning Electron Microscopy (SEM)

Examines the microstructure of molded materials for defects, voids, or grain alignment issues.

Density Variations

Archimedes Principle or Pycnometry

Measures density distribution within the part to identify inconsistencies in material compaction.

What Our Customers Say about Frigate

I would strongly recommend Frigate to anyone who wants to do Rapid Prototyping, and 3D Printing and take their ideas to manufacturing. One firm doing all kinds of Product Development!

Thank you so much for your great support so far. Overall, the sheet metal work of the Plotbot Pro was done in an awesome way.Special Mention: The powder coat looks cooler!

The next disruption is happening in Prototyping & Manufacturing on-demand and Frigate is leading the way!I personally believe the Frigate's way of IIOT enabled cloud platform with Al.

I am absolutely happy to work with supplier like Frigate who were quite proactive & result oriented . Frigate has high willingness team who has strong know how & their passion towards the products & process were absolutely thrilling.

Working with Frigate has been great. Their proactive, results-driven approach and expertise shine through in every project. It's been a pleasure collaborating with them.

Having Doubts? Our FAQ

Check all our Frequently Asked Question

How does mold design influence the manufacturing of complex parts in compression molding?

Mold design significantly affects the ability to create intricate parts. Frigate employs advanced mold techniques to optimize shapes and dimensions, reducing issues related to undercuts and ensuring accurate part formation.

What are the common challenges in achieving dimensional accuracy during production runs?

Variations in material properties and process parameters can make maintaining consistent dimensional accuracy challenging. Frigate uses real-time monitoring systems to track and adjust conditions, ensuring parts consistently meet specifications.

How does Frigate minimize waste during the compression molding process?

Frigate implements efficient material usage strategies and precise process controls to reduce scrap rates. This approach lowers costs and promotes sustainability by minimizing environmental impact.

What steps are taken to enhance production efficiency and reduce lead times?

Frigate focuses on streamlined workflows and quick setup techniques to improve production efficiency. This optimization reduces downtime between runs, allowing faster turnaround times to meet customer demands.

How does Frigate ensure the performance and reliability of materials used in compression molding?

Frigate selects materials based on specific performance criteria and conducts thorough testing to ensure reliability. This process ensures that chosen materials withstand operational conditions and maintain functionality throughout their lifecycle.