Laser cut rubber is an awesome way to produce flat profile components for gaskets and seals. Unlike cutting metal alloys which are stable during manufacturing, rubber materials do add some challenges, but adjusted too, the results provide quality parts in a wide array of industrial applications and high technology devices. The use of rubber can be found going back to ancient Mesoamerica pre-1500 BCE where Olmecs, Aztecs and Mayans were the first known civilizations to use rubber for adhesive, waterproofing materials and even for use as balls for games. The modern use of rubber dates to 1839, when Charles Goodyear, discovered the process now called vulcanization which is a method of heating rubber with sulfur to create a compound that is more stable with elastic properties and resistant to heat and cold. Soon after, many of the uses for rubber such as tires, seals, gaskets, hoses, insulation and waterproofing were being done. Over many decades, the technology to harvest raw rubber materials and transform it into hoses, sheets, blacks etc., has grown along with the technologies to process rubber components. Laser cutting technology is one of them, but others such as die-cutting, extrusion and molding are used as well. Laser cutting rubber is different from other methods and has found its niche in manufacturing of it. Let’s explore more on how this is done.
Advantages of Laser Cutting Rubber over Die-Cutting
Today, rubber is processed into components using a range of methods depending on the application, material type (natural vs. synthetic), volume needs, and precision requirements. Laser cutting rubber will result in well-defined flat components that hold tolerances that go beyond its main competitor, die-cutting. Other methods like molding processes, extrusion and calendaring are done for specific applications and or rubber products. For flat rubber parts, die-cutting and laser technology using ultraviolet systems are the prime methods being used. UV systems are versatile in cutting rubber compounds as well as metal alloys, adhesives, polymers and materials like alumina ceramic and grafoil, and many others. Although each has great characteristics, using laser methods offers advantages such as shown on the following table:
| Feature | Laser: Cutting with Light | Die-Cut: Old School Standby |
|---|---|---|
| Tooling Costs | No tooling- Just cad data and material to start. | Requires steel-rule dies or rotary tooling. It can be costly for changes. |
| Precision & Detail | Great for tight tolerances and micro features. {/- .003” to +/- .005” (mils) | Limited by die complexity. Sharp angles and tiny details can be tricky. +/0 .005” to +/- .015” (mils) |
| Design Flexibility | Rapid design changes with minimal downtime. Prototyping dream! | Changes = new die. That means added cost and lead time. |
| Edge Quality | Smooth, sealed edges with minimal burring. Especially on thin rubber. | Can leave rougher or crushed edges. Needs post-processing sometimes. |
| Speed/Prototype/Volume | Fast set-up-Perfect for prototypes, but slower on mass production. | Set-up and tooling costs, slower prototyping. Much faster on production. |
| Material Versatility | Handles a wide range of rubbers (even foam or laminated layers). | Limited to what the die can handle cleanly. |
The Versatility of Laser Technology Through Rubber
Manufacturing rubber components are being made using laser technology for a very host of industries and unique applications. Some are done for R&D and prototypes, but there are projects in production volumes that need to be done by laser. The quality and use of these parts are highly important, which laser cutting services are the best and only solution. Let’s take a glimpse of how laser cut parts are being applied by industries.
- Connectivity Products: Compounds of nitrile and silicon rubbers are being used in connectivity products for guiding connector pins.
- EV Batteries: Silicon rubber are being used as gaskets in thickness of .030” to 60mils.
- Medical Devices: Rubber gaskets for wearable and diagnostic devices.
- Heavy Industry: Gaskets and seals made of rubber for valves and enclosures. For use as vibration insulators for rotary equipment, pumps and motors.
- Semiconductor Manufacturing: Rubber gaskets being used in wafer processing equipment. Precision rubber gaskets are also being used in deposition chambers.
- Defense and Military Electronics: Seal and dampener rings in ruggedized electronics and sensors. Laser-cut EMI/RFI shielding gaskets in tactical communication devices made from conductive rubber composites.
The nature of rubber being pliable can create challenges to manufacturing components to high precision. With the expertise of laser cutting specialists, the challenges are being solved with repeatable and qualified results. The industries mentioned above require consistent and accurate manufacturing techniques, and with laser cutting, they have partnered with a solid resource.
Conclusion
While die-cutting has long been a standard in manufacturing rubber components, the finesse of laser cutting surpasses it in precision and adaptability. Laser cutting eliminates the need for physical tooling, enabling faster prototyping and seamless adjustments to intricate designs. Furthermore, it excels in producing clean edges and exact tolerances, which are vital in industries like medical devices and semiconductor manufacturing. Unlike die-cutting, which can struggle with the pliable nature of rubber, laser cutting offers a non-contact method that preserves the material’s integrity while achieving unparalleled accuracy. As industries demand greater innovation and reliability, the choice between these methods becomes clear—laser cutting doesn’t just solve the challenges; it transforms possibilities into precision-crafted realities.