Answer: The processing conditions can be optimized to match the tool design, part geometry, and material but each presents limitations. Injection process times are driven by material. Silicone parts can often be released with no draft angle or even undercuts due to the high elongation and low modulus that save time on actions but knock out pins may often damage parts. Silicone part removal is often done by automated brush, hand pull, compressed air, or another way that may take additional time compared to plastic.

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Silicone, especially liquid silicone will conform well to just about any mold shape that can be dreamed up, the difficulty is typically in the mold making process. In the prototyping sector, we see a lot of cutting edge design concepts that push the envelope with features that are very small and precise. Every molder has their own specialty and also their own limitations. At Albright we specialize in quick-turn micro medical device parts molded in liquid silicone rubber. One design limitation that we frequently contend with is the size and geometry of micro features, we like to use "The 3X Rule", which basically means that if you have a microscopic opening in your part design (which would be reflective of a raised boss in the mold) the overall height of that feature shouldn't exceed three times the diameter (or side length) of the feature. That would mean that if you wanted to form a 0.005" diameter hole in your molded part, you wouldn't want to go much more than 0.015" deep into the part, from a tool making standpoint.

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