In todays crowded marketplace, speed, accuracy, and tidy surfaces matter more than ever, especially when silicone parts end up in health gear, cars, lunch boxes, or cameras.
Thats why Ami Polymer Pvt. Ltd. now leans on Liquid Silicone Rubber (LSR) injection moulding instead of the older High Consistency Rubber (HCR) and compression methods.
While the traditional approach still needs hours of hands-on work and can leave rough edges, LSR allows almost fully automated runs that turn out flawless, flash-free parts in record time.
With better flow, tighter measurements, and tighter process control, Ami Polymer gives its clients top-quality pieces, easy growth, and sensible savings, raising the bar for what silicone moulding can achieve.
Why Ami Polymer preferred LSR injection moulding over compression & HCR moulding?
INTRODUCTION : Ami Polymer Pvt Ltd Liquid Silicone Rubber (LSR) injection moulding uses a low-viscosity, two-component (platinum-catalysed) system to produce high-precision elastomer parts.
In contrast, High Consistency Rubber (HCR, aka solid silicone) and compression moulding use manual techniques and higher-viscosity materials. Understanding their differences is key to choosing the right process for your product.
Viscosity & Material Flow: LSR: Low viscosity enables flow into thin walls and complex geometries with ease HCR/Compression: High viscosity requires manual insertion and trimming, limiting flow ability
Production Speed & Automation:
Cycle Time:
- LSR: 10–90 seconds per part with automated robots
- Compression/HCR: 3–10 minutes per part, manual work dominates
Automation Potential:
- LSR: Fully automated — metering, injection, demoulding, inspection.
- HCR/Compression: Mostly manual; secondary trimming is common
- Impact: For medium to high production runs, LSR drastically lowers labor cost and boosts throughput.
Part Quality & Precision
- LSR enables: Thin walls (<0.5 mm), intricate features, optical surfaces Tight tolerances (±0.02 mm), minimal flash due to cold-runner system
- HCR/Compression results: Flash common, manual trimming adds time and variability Air entrapment, voids, less dimensional
- Impact: For precision parts (medical, optical, seals), LSR delivers unmatched consistency and quality.
Cleanliness & Contamination Risk:
LSR: Delivered in sealed drums and pump-fed; no direct manual handling reduces contamination HCR/Compression results: Flash common, manual trimming adds time and variability Air entrapment, voids, less dimensional
Impact: Critical for fields demanding sterility—medical, food, baby care.
Design Freedom
LSR advantages :
Over-moulding onto plastic/metal in the same mold
Undercuts, flexible geometries, multi-color via inline pigment mixer High clarity optical parts via precision moulds
HCR/Compression constraints:
- Bonding separate parts manually
- Thick part limitations, manual demoulding
Impact: Enables innovative product designs and multifunctional components.
Cost Analysis :
LSR : Higher initial tooling, but fast amortization with volume
HCR/Compression results: Lower tooling costs, but expensive labor and slow cycles
Break-even volume: Typically around 5,000–10,000 parts—beyond that, LSR becomes more economical .
Performance & Durability
LSR Properties:
Temperature range from –50 °C to 250 °C; resistant to UV, ozone, chemicals, moisture Excellent electrical insulation, tear strength, elongation
HCR/Compression constraints:
Similar properties but slower stable cure; possible residual strain, reduced elongation
Impact: LSR parts are more reliable and consistently high performance immediately after moulding.
Interpretation for Management:
LSR provides consistent high-quality parts faster and cheaper at scale, enabling entry into modern product segments
Real case examples:
Medical Industry Example
Product: Neonatal silicone breathing mask
Challenge: Extremely thin wall section (< 0.5 mm), must be biocompatible and free of defects.
Compression/HCR Outcome: Poor wall consistency, high scrap rate, visible flash, could not meet ISO 10993 standards
LSR Outcome: Fully automated process, no flash, perfect surface quality, passed biocompatibility tests — production scaled to 500,000 parts/year.
Automotive Industry Example
Product: Automotive electrical connector seal (weatherproof)
Challenge: Part with integrated sealing lips, requires high elasticity and UV resistance; 1 million+ parts/year.
Compression/HCR Outcome: Manual post-curing, uneven lips, poor repeatability.
LSR Outcome: Fully automated 32-cavity mold; cycle time 28 seconds; parts used in BMW and Audi vehicles — zero field failures.
Declaration: Ami Polymer Pvt. ltd. — commitment to advanced LSR technology
At Ami Polymer Pvt. Ltd., we are committed to offering the highest quality, precision-engineered silicone products to meet the evolving needs of advanced industries such as medical, healthcare, automotive, food & beverage, optics, and more.
As part of this commitment, we have invested in and operate state-of-the-art Liquid Silicone Rubber (LSR) Injection Moulding Machines within our manufacturing facilities.
Our adoption of LSR technology is based on clear strategic and technical advantages:
- Superior precision and surface finish for complex geometries
- Fully automated production with minimal human handling — essential for cleanroom and medical-grade components
- Fast cycle times and scalable production — allowing us to meet both prototype and high-volume demands Consistent quality with reduced post-processing and waste.
At Ami Polymer, we prefer and promote the use of LSR technology over traditional Compression Moulding or HCR processing wherever technical feasibility and customer applications allow — ensuring that our customers receive next-generation, precision-moulded silicone components with:
- Lower total cost of ownership
- Improved performance and reliability
- Faster delivery timelines
By leveraging LSR, we enable innovation and competitive advantage for our customers across India and global markets.
We are proud to declare that Ami Polymer Pvt. Ltd. is fully equipped and experienced in Liquid Silicone Rubber (LSR) processing — and ready to support your advanced silicone moulding needs.
For any queries or project discussions related to LSR moulded components, please contact us — our team will be happy to collaborate with you.