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Durable Silicone Foam: The Ultimate Alternative to Urethane Products¹

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Product DescriptionFoamed Silicone: A Lightweight, Durable ElastomerFoamed silicone is a high-performance, porous elastomer that combines the durability and flexibility of solid silicone rubber with the lightweight advantages of a cellular foam structure. Manufactured using advanced processes—such as chemical foaming, gas injection, or mechanical aeration—it forms a consistent network of air-filled cells that deliver an exceptional balance of strength, cushioning, and adaptability.Key Features30–70% lighter than solid siliconeHighly compressible, accommodating up to 80% deformationOutstanding thermal and chemical resistanceRetains silicone's inherent advantages, including resistance to UV, ozone, and extreme temperaturesUnlike conventional foams, foamed silicone preserves the mechanical integrity of solid silicone while enhancing insulation, sealing, and cushioning performance. Its unique combination of properties makes it ideal for applications demanding weight reduction, long-term reliability, and superior functionality in harsh environments.Key features and benefitsReliable Performance in Extreme EnvironmentsFoamed silicone retains its elasticity and structural stability even after repeated thermal cycling, mechanical stress, and long-term compression. This makes it a trusted material for demanding applications where durability and resilience are critical.Lightweight & Highly CompressibleEngineered with a low-density cellular structure, foamed silicone is perfectly suited for weight-sensitive designs. Its high compressibility and quick recovery deliver reliable sealing, gasketing, and vibration damping, whether under constant load or dynamic conditions.Superior Thermal Insulation & Temperature StabilityThe foam's air-filled matrix provides excellent thermal insulation, reducing heat transfer while maintaining stability across a wide temperature range (–60°C to +200°C+). From extreme cold to intense heat, foamed silicone ensures consistent, reliable performance.Exceptional Environmental & Chemical ResistanceNaturally resistant to UV, ozone, moisture, and oxidation, foamed silicone also withstands oils, solvents, and harsh chemicals. Its long-lasting durability makes it an ideal solution for outdoor, industrial, and corrosive environments.While production materialsilicone foam padsheet roll materialTechnical Specifications(Custom configurations available upon request.) PropertyValueDescriptionMaterial TypeSilicone SpongeHigh-performance elastomer designed for sealing, cushioning, and insulation.Cell StructureClosed CellPrevents moisture, air, and dust ingress—ideal for sealing and outdoor use.Density(BS EN ISO 845, ASTM D3574)19.4 lbs/ft3 (310 kg/m3)Balanced density for structural integrity and flexibility.Compression Stress @ 25% Strain(ASTM D1056)5.8 psiLow compression force for effective sealing under minimal load.Elongation to Failure(BS EN ISO 1798, ASTM D412)90%High flexibility and stretchability before breaking.Compression Set(22 hrs @ 158°F / 70°C, 50%)(BS EN ISO 1856)<1%Excellent compression recovery; maintains shape after prolonged load.Thermal Conductivity(DIN EN 993-15)0.099 W/m·KProvides thermal insulation; minimizes heat transfer.Flame Rating(UL 94)UL94 V-0 @ 1.5 mm thicknessOutstanding flame resistance; self-extinguishing material.Ozone ResistanceYesResistant to degradation in ozone-rich environments.UV ResistanceYesSuitable for prolonged outdoor exposure without material breakdown.Production activitiesSilicone Foam Production OverviewSilicone foam is a lightweight, highly adaptable material valued for its flexibility, durability, and cellular structure. Formed by foaming liquid or solid silicone compounds, it creates a soft, resilient matrix available in both open-cell and closed-cell variants—enabling customized solutions for a wide range of applications.With exceptional thermal stability, weather resistance, electrical insulation, and cushioning performance, silicone foam consistently delivers reliable results in demanding conditions. Its versatile properties make it a material of choice across industries such as automotive, aerospace, electronics, medical, construction, and telecommunications, where durability and adaptability are critical.Strictly controlled processing1.FormulationProduction begins with a carefully engineered silicone rubber base, combined with curing agents, blowing (foaming) agents, and functional additives such as flame retardants, pigments, or conductive fillers. Each formulation is tailored to deliver the desired mechanical, thermal, and chemical performance.2.MixingThe ingredients are thoroughly blended using high-shear mixing equipment to achieve uniform dispersion. Critical parameters—such as viscosity and reactivity—are precisely controlled to ensure stable processing and consistent product quality.3.Foaming & CuringThe compound undergoes a chemical foaming reaction, generating gas bubbles that expand the silicone into a porous, cellular structure. At the same time, crosslinking (curing) locks in the foam's geometry and mechanical properties.Common production methods include:Batch molding (compression or transfer)Continuous extrusionLiquid Injection Molding (LIM) for LSR-based foams4.Post-Curing (Optional)To enhance mechanical strength, improve thermal stability, and eliminate residual volatiles, the foam may undergo post-curing in a controlled oven environment.5.Cutting & ShapingThe cured foam is converted into final products—such as sheets, rolls, strips, gaskets, or custom profiles—using die-cutting, CNC machining, or precision fabrication, depending on application needs.6.Quality ControlEach batch is rigorously tested to verify compliance with specifications. Key evaluations include:Density & compression set7.Tensile strength & elongationFlammability resistanceThermal conductivityApplication-specific mechanical and environmental performanceQuality control 1. Raw Material InspectionAll raw materials are procured from certified suppliers and undergo thorough testing for purity, consistency, and traceability before entering production. Retention samples are archived to support future reference and ongoing quality verification.2. In-Process MonitoringThroughout mixing and foaming, key process parameters—such as temperature, material ratios, and expansion rates—are continuously tracked. Visual checks detect surface imperfections like bubbles, discoloration, or other defects, while real-time measurements ensure consistent foam density and precise dimensional control.3. Laboratory TestingEvery production batch is tested in our quality control laboratory according to recognized international standards, including:Density: ISO 845 / ASTM D3574Compression Set: ISO 1856Compression Stress: ASTM D1056Elongation: ISO 1798 / ASTM D412Thermal Conductivity: EN 993-15Flame Resistance: UL94 V-0 / EN 45545-2Additional assessments may include water absorption, UV resistance, and ozone resistance.4. Final Product InspectionBefore dispatch, all products are subjected to detailed visual and dimensional checks. Adhesive-backed items undergo peel strength testing to confirm bonding integrity. Only products meeting all quality standards are approved, QC-marked, and assigned a unique batch number for full traceability.5. Packaging Quality ControlProducts are packaged in clean, moisture-resistant materials to preserve quality during storage and transport. Each package is clearly labeled with the product name, lot number, production date, and handling instructions for safe and accurate delivery.6. Full TraceabilityComprehensive records are maintained for every batch, covering raw materials, process parameters, test results, inspection data, and shipping documentation—ensuring complete traceability from production to delivery.7. Commitment to Continuous ImprovementWe actively pursue ongoing quality enhancement through customer feedback, internal audits, and regular staff training. This commitment drives process optimization and ensures we consistently surpass customer expectations.Packaging & ShippingProperly packingTimely delivery1. Cleanroom or Dust-Free Packing AreaPerform final packing in a clean or controlled environment to prevent contamination from dust, debris, or moisture.Wipe down foam surfaces (if required) to remove loose particles. 2. Primary Protection – Inner PackagingFor sheets, pads, or rolls:Stack neatly and separate layers with release liners or PE film to prevent adhesion or surface damage.Use plastic wrap, PE bags, or vacuum-sealed pouches for moisture and dust protection.For die-cut gaskets or CNC parts:Place parts in anti-static trays, foam layers, or individual plastic bags depending on the sensitivity and shape. 3. Secondary Packaging – Outer ProtectionUse corrugated cardboard boxes or plastic crates based on transport distance and product fragility.Add EPE foam, bubble wrap, or corner protectors inside to prevent shifting or compression during transit.For bulk rolls, use reinforced cartons with center supports or reels to maintain shape. 4. LabelingEach package should include:Product name and code Specification and quantityBatch/lot numberProduction dateHandling instructions (e.g., "Do not compress," "Keep dry," "Fragile")5. Palletizing (if applicable)Arrange boxes securely on wooden or plastic pallets.Wrap the entire pallet with stretch film and apply edge guards to protect corners.Use straps to hold boxes tightly in place, especially for international shipping. 6. Delivery MethodChoose delivery options based on product sensitivity:Local delivery: Use vans with weather protection.Domestic shipping: Choose courier or logistics services with reliable handling.International shipping: Use export-grade packing with moisture-proof and impact-resistant features. Air shipping for urgent and lightweight goods; sea shipping for bulk orders. 7. Environmental and Storage ConsiderationsStore and transport in conditions away from high humidity, UV exposure, and direct heat.Maintain temperature below 40°C and humidity below 60% RH whenever possible.ApplicationsIndustry ApplicationsEV & Energy StorageIdeal for battery cushioning pads and fire barriers, offering flame-retardant performance (UL94 V-0 compliant) to enhance safety in electric vehicles and energy storage systems.Electronics & 5G InfrastructureUsed in EMI shielding gaskets for high-frequency communication devices, including 5G base stations, ensuring signal integrity and interference protection.Aerospace & TransportationProvides lightweight thermal and acoustic insulation for aircraft interiors, reducing weight while improving passenger comfort and energy efficiency.Medical & Wearable DevicesServes as soft, biocompatible padding (ISO 10993-5 compliant) for prosthetics and medical wearables, ensuring patient comfort and safety.Innovation Spotlight: DC800 Series by Dachuang KehuaA breakthrough in silicone foam technology, the DC800 Series eliminates traditional chemical foaming agents with self-foaming silicone innovation, delivering:Customizable Density (0.05–0.5 g/cm3) – Adaptable for diverse performance needsZero VOC Emissions – Fully REACH-compliant, supporting sustainable manufacturing30% Faster Curing – Reduces production time while maintaining high-quality resultsThis cutting-edge advancement redefines efficiency, sustainability, and performance in next-generation silicone foam applications.Company ProfileSilicone Expert-Dachuang KehuaDachuang Kehua New Materials Technology Co., Ltd. – Your Trusted Silicone Solutions PartnerAs a leading innovator in silicone material technologies, Dachuang Kehua combines cutting-edge material science with precision engineering to deliver superior sealing, insulation, protection and cushioning solutions for demanding applications across industries.Our Comprehensive Silicone Solutions Portfolio:1. Custom Silicone Foam ProductsClosed-cell and open-cell foam formulationsSpecialized in sealing, shock absorption, thermal management and environmental protectionAvailable as sheets, rolls, gaskets or custom die-cut components2. High-Performance Solid Silicone ComponentsPrecision-engineered for exceptional mechanical strengthSuperior weather and chemical resistanceIdeal for automotive, industrial and medical applications3. Ultra-Soft Silicone Gel ProductsExceptional resilience and cushioning propertiesWidely used in:Electronics thermal managementMedical device paddingImpact absorption systems4. Semi-Fluid & Potting CompoundsAdvanced formulations for encapsulation and bondingExcellent electrical insulation propertiesSuperior moisture resistance and thermal stability5. Adhesive-Backed Silicone SolutionsHigh-performance silicone sponge/foam with adhesive backingEnables fast, reliable assemblyEnsures consistent sealing performance6. Precision Fabrication ServicesState-of-the-art die-cutting capabilitiesCNC and laser machining expertiseCustom fabrication of complex components including:Precision gasketsThermal interface materialsSpecialized seals7. Specialty Silicone FormulationsFlame-retardant grades (meeting strict industry standards)Low-outgassing and FDA-compliant optionsElectrically insulating formulationsCustom material properties to meet specific requirements8. Custom R&D ServicesCollaborative development processFull-cycle support from:Initial formulationPrototypingPerformance testingFinal product validationIndustries We Serve:? Automotive ? Aerospace & Defense ? Electronics ? Rail Transportation? Medical Devices ? HVAC/R ? Marine ? New Energy TechnologiesWhy Choose Us?Other ProductsOEM/ODM capabilitiesCompetitive pricing & bulk discountsFast shipping & customs clearance supportTurnkey project solutionsWheel LoadersBulldozersMotor GradersRoad RollersForkliftsFAQQ1: What types of silicone materials do you produce?We offer a broad range of silicone materials, including closed-cell and open-cell silicone foam, solid silicone rubber, silicone gel pads, semi-fluid silicones, and adhesive-backed silicone tapes. Specialty options such as flame-retardant, low-outgassing, and custom-formulated grades are also available.Q2: Can you customize products to meet our specific requirements?Yes. We provide full customization in thickness, density, color, shape, adhesive backing, and packaging. Custom formulations can also be developed to meet specific mechanical, environmental, or regulatory needs.Q3: Do your silicone products comply with international standards?Absolutely. Depending on the product and application, our materials meet or exceed certifications such as UL94 V-0, EN45545-2, NFPA 130, FDA, REACH, and RoHS.Q4: What are the common applications for your silicone foam and rubber products?Our products are widely used in automotive sealing, electronic cushioning, rail and aerospace insulation, medical devices, lighting enclosures, HVAC systems, and marine/military equipment.Q5: Do you offer precision fabrication services like die-cutting or CNC processing?Yes. We provide die-cutting, CNC cutting, laser cutting, and lamination services. This enables us to deliver high-precision, ready-to-use parts and gaskets tailored to your specifications.Q6: What is your typical lead time for custom orders?Lead times vary by order complexity and quantity. Standard items typically ship within 5–7 working days, while custom products may take 7–15 working days. Rush production is available upon request.Q7: Can we request material samples before placing an order?Yes, we provide free samples for testing and validation. Just send us your material requirements and shipping information.Q8: How do you ensure consistent product quality?We follow rigorous, ISO-certified quality control procedures, including raw material inspection, in-process monitoring, mechanical and thermal testing, and final product inspection, ensuring consistent quality and reliable performance.

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