process is a key technology used to produce three-dimensional logos and patterns. It is widely applied in industries such as garments, toys, and electronic products. Although the steps may appear simple, every stage demands precise control-any minor oversight can lead to hidden failures.
1. Mixing and Degassing: Air Bubbles – the "Invisible Killer"
with the curing agent, insufficient stirring or incomplete vacuuming leaves air bubbles trapped in the mixture. These bubbles form pits or cavities after vulcanization, compromising the integrity of the pattern.
Problem Impact: Air bubbles reduce the local support strength of the silicone, causing the formed part to collapse. Bubbles at pattern edges may also cause blurring or breakage.
Solution: Follow the mixing ratio strictly (e.g., 10:1 or 100:2), and stir until uniform with no streaks.
Control vacuum time within 5–10 minutes-too short leaves bubbles; too long may cause premature curing. End the vacuum process only when the pressure gauge points to the negative range.
2. Coating and Pressing: Uneven Thickness Triggers Chain Reactions
After pouring silicone into the mold, the scraper must evenly spread the layer to a thickness of 0.1–0.3 mm.
Problem Impact: If too thick, silicone overflows from the mold; if too thin, support strength is insufficient. Uneven thickness causes inconsistent heating during vulcanization, leading to partial under-curing or over-curing, which affects pattern clarity and adhesion.
Solution: Use a calibrated scraper to precisely control thickness, ensuring even coating without accumulation or gaps.
When covering with Teflon film, press slowly from the center outward to expel air and prevent bubble entrapment.
3. Vulcanization and Demolding: Parameter Deviations Cause Sticking or Tearing
Vulcanization temperature and time must match material specifications (e.g., 125℃–215℃ for several minutes). Any deviation may cause sticking to the mold or incomplete curing.
brittle and prone to tearing during demolding; insufficient temperature leads to incomplete curing and poor pattern transfer.
Solution: Preheat equipment to stabilize the working temperature.
Demold while still warm using insulated tools to carefully lift off the Teflon film. If demolding is difficult, check mold cleanliness or adjust vulcanization settings.
4. Transfer Stage: Peeling Technique Determines Pattern Integrity
During the transfer using low- and high-adhesion films, improper peeling angle or force can cause misalignment or damage.
Problem Impact: Forceful peeling stretches and distorts the pattern; insufficient adhesion prevents complete transfer.
Solution: First peel off the low-adhesion film slowly along the pattern's direction, then apply the high-adhesion film firmly. When transferring to fabric, maintain proper conditions (e.g., 150℃ for about 10 seconds).
