Investing in Precision: Bringing Liquid Silicone Rubber Moulding In-House

Our latest investment in Liquid Silicone Rubber (LSR) moulding is an example of us bringing manufacturing in-house. By developing this capability in Ireland, we are increasing control over one of the most critical components used in many dispensing systems while reducing our reliance on external suppliers.

Although vented pumps are one of the first applications for this technology, the capability opens the door to a range of possibilities for future product development.

What is Liquid Silicone Rubber?

Liquid Silicone Rubber is a high-performance material used in applications where precision, durability and chemical resistance are essential. Unlike many conventional elastomers, LSR maintains its flexibility over a wide temperature range, resists repeated compression and is highly resistant to cleaning chemicals, alcohol-based sanitisers and environmental exposure.

These characteristics make it an ideal material for components that must create reliable seals, maintain consistent performance over thousands of dispensing cycles and withstand demanding hygiene environments.

In dispenser technology, even small silicone components can have a significant impact on product performance. Parts such as seals, valves and pump components influence dispensing accuracy, prevent leaks and contribute to the long-term reliability of the entire system.

Moving Beyond Supplier Dependence

Historically, silicone components were sourced from specialist external suppliers. While this approach provided access to high-quality parts, it also meant that production schedules, lead times and design iterations were dependent on outside manufacturing capacity.

As supply chains became increasingly unpredictable in recent years, relying on overseas suppliers grew to be a liability.

By investing in LSR moulding in Ireland, OPHARDT gains greater control over both product development and production. Engineering teams can work more closely with manufacturing, allowing ideas to move to production more efficiently.

This level of vertical integration strengthens resilience and provides greater flexibility when responding to customer demand.

Building a New Manufacturing Capability

Introducing Liquid Silicone Rubber moulding is far more complex than installing another injection moulding machine.

LSR behaves very differently from conventional thermoplastics. It requires specialised equipment capable of accurately mixing two liquid components, delivering precise shot sizes and controlling curing conditions within the mould. Small variations in temperature, pressure or material flow can influence the quality of the finished part.

As Design Engineer Tony Cotter explains:

“Liquid silicone injection moulding requires a different approach to mould design and part extraction. Thermal expansion of the mould steel during curing means careful consideration must be given to plate guidance and cavity-to-core alignment. Each cavity also requires air evacuation before injection, with precisely positioned seals and vacuum channels to ensure the parts fill correctly. Venting channels are measured in microns and are approximately three times smaller than those used in thermoplastic injection moulding. Part extraction is then carried out using automated end-of-arm tooling, making extraction equipment a significant part of the overall capital investment.”

Developing this capability therefore required investment not only in moulding equipment but also in tooling, automation, process development and manufacturing expertise. Each stage had to be validated to ensure components consistently meet the performance standards expected in healthcare and commercial hygiene applications.

Better Products Through Greater Control

Greater control over the manufacturing process also improves consistency. Development of a product can be monitored throughout manufacturing, helping ensure every component performs as intended.

Supporting Cost Efficiency Without Compromising Quality

Producing silicone components in-house reduces dependence on external supply chains, shortens transportation routes and removes many of the costs associated with outsourced production. At the same time, closer collaboration between design and manufacturing helps optimise components for efficient production from the earliest stages of development.

Looking Ahead

While vented pumps are an important first application, this capability creates opportunities for a wider range of precision silicone components across future dispenser platforms. As customer needs evolve, having this expertise in-house gives OPHARDT greater flexibility to innovate, refine designs and bring new ideas to market more efficiently.