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LSR Overmolded Single Canister Respirator Mask – Cold-Runner Vertical Molding Solution

Single canister respirator masks rely on a soft silicone face seal permanently bonded to a rigid plastic frame. The seal must fit the face comfortably, hold an airtight seal under breathing pressure, and stay bonded through repeated use, cleaning, and disinfection. Conventional methods, such as molding the silicone separately and then gluing or mechanically assembling it, add labor, create weak bond lines, and introduce leak paths. Low-cavity overmolding with open runners also wastes expensive LSR and leaves flash and gate marks on the sealing edge that touches the skin.

Cavities

4

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Core Technology Breakdown

TYM Vertical LSR Injection Molding Machine

The vertical clamping layout suits insert overmolding. Plastic mask frames sit securely in the lower mold under gravity, which prevents insert shifting during injection.

- ▸ Vertical clamping and injection layout. Operators or robots can load inserts easily, and the frames stay stable during mold closing.
- ▸ Shuttle / dual-station lower mold option. One station is loaded with new frames while the other is molding, which cuts idle time between cycles.
- ▸ LSR metering and mixing system with a precision plunger injection unit.
- ▸ Closed-loop servo control keeps shot weight consistent across all 4 cavities.
- ▸ Low-pressure, controlled injection profile protects the plastic insert from deformation or damage.

The machine delivers the steady clamping force and injection precision required for thin-wall, high-cavitation IV cannula connector molding.

Cold-Runner Precision Injection Control

4-Cavity Cold-Runner Overmolding Mold

- - ▸ Cold-runner system with needle-valve cold nozzles LSR stays uncured until it enters the cavity, so there are no runners to trim or scrap.
  - ▸ Sprueless, gate-free design. No gate vestige is left on the face-contact sealing lip.
  - ▸ Precision insert location. Each frame is positioned accurately so silicone wall thickness stays uniform around the whole face seal.
  - ▸ Tight shut-off at the plastic/silicone interface. Flash cannot creep onto the rigid frame or the canister connection area.
  - ▸ Optimized venting prevents trapped air at the deep contours of the nose bridge and chin.

LSR-to-Plastic Bonding

The rubber coating molding process is the heart of the system. Our design features:

- ▸ Self-adhesive LSR gradesm bond chemically to 【PC / PA / PP – confirm insert material】 frames during vulcanization. No primer or glue step is needed.
  - ▸ Bonding is formed in-mold. There is no secondary assembly and no bond line that can peel or leak.
  - ▸ Mold temperature and cure time are tuned to reach full adhesion strength without warping the plastic insert.

The in-mold overmolding process produces respirator masks with a clean, flash-free face seal permanently bonded to the frame, ready for canister assembly and packaging without secondary gluing or deflashing operations.

Key Benefits at a Glance

Benefit	Detail
One-Step Overmolding	Silicone face seal is molded and bonded to the plastic frame in one cycle. No gluing or assembly.
4-Cavity Output	Four finished masks per cycle on a single vertical machine.
Zero-Waste Molding	Cold-runner needle-valve system means no sprues, no runners, and near 100% LSR utilization.
Flash-Free Sealing Lip	Gate-free design and tight shut-off leave a clean, comfortable face-contact edge.
Strong, Leak-Free Bonding	In-mold chemical adhesion replaces glue lines that can peel or leak
Stable Insert Positioning	Vertical clamping keeps frames in place for consistent silicone thickness.
Lower Labor Cost	No deflashing, gate trimming, or separate seal assembly.

Pressure cooker silicone o ring mold - TYM

Technical Specifications

Parameter	Specification
Machine Type	TYM Vertical LSR Injection Molding Machine
Molding Process	LSR overmolding (insert molding)
Injection System	Servo-driven plunger, closed-loop control
Mold Cavities	4 cavities, cold-runner design
Gate Type	Needle-valve cold nozzles
Gate/Flash Condition	Sprueless, no flash
Insert Material	【PC / PA / PP】 rigid mask frame
Overmold Material	Self-adhesive Liquid Silicone Rubber (LSR)

One Supplier. One System. One Guarantee.

We deliver the vertical machine, the 4-cavity cold-runner overmolding mold, and the automation as one complete system from a single source. You do not need to source them from separate vendors.

No Integration Headaches:

The machine and mold are designed together to ensure optimal performance and seamless compatibility.

Single-Point Responsibility:

We take full accountability for the overall quality, performance, and after-sales service of the entire system.

Pre-Tested and Validated:

The complete system is rigorously tested, tuned, and validated as a single functioning unit before delivery.

Faster Ramp-Up:

With process parameters already configured, your team can start mass production within days of installation.

Proven in Production

Our 4-cavity LSR overmolded respirator mask solution is running in production and delivers:

High Yield Rate:

Consistently achieves industry-leading pass rates during both visual and dimensional inspections.

Uniform Seal Thickness:

Precise insert location and balanced filling keep the face seal consistent for reliable fit.

Minimal Post-Processing Requirement:

Produces flash-free parts with minimized gate marks, reducing the need for deflashing or gate trimming.

Long-Term Process Stability:

Sprueless cold-runner design maintains stable output without process drift over extended production runs.

Made for Global Standards

CE-Certified Safety

All electrical components and integrated safety systems are fully CE-certified, guaranteeing safe and reliable operation in global manufacturing environments.

FDA & EU Compliant Processing:

Engineered to meet strict hygiene standards, our system is fully capable of processing food-grade and medical-grade LSR materials compliant with FDA and EU regulations.

ISO 9001 Quality Management:

Our entire workflow—from initial R&D and mold design to manufacturing and final testing—is strictly governed by ISO 9001 quality management protocols.

Comprehensive Global Support:

We provide complete English technical documentation, intuitive English PLC interfaces, and highly responsive global technical support for commissioning and troubleshooting.

Frequently Asked Questions

Projects

Can this system produce different mask sizes or models?

Yes. The mold can be customized for different face sizes (S/M/L), seal profiles, and silicone hardness. Injection parameters are fully programmable for quick changeovers. For best cycle time and quality, we recommend a dedicated mold for each model.

How strong is the bond between silicone and the plastic frame?

Using self-adhesive LSR matched to your frame material, the bond forms chemically during curing. Properly processed parts typically show cohesive failure, meaning the silicone tears before the bond does. We can run bond-strength tests on your frame material during sampling.

Can my existing plastic mask frames be used as inserts?

In most cases, yes. Send us your frame drawings or samples and we will check material compatibility, insert positioning, and shut-off design, then propose any small design changes needed.

What training and support do you provide?

We provide on-site training for operators and maintenance technicians, full documentation (machine manual, mold maintenance guide, process parameters), and remote technical support. Our engineers are available worldwide for on-site commissioning.

Ready to Transform Your Nipple Production?

Contact us today for a free consultation, process analysis, and quotation.

We can provide production simulations, sample molding, and ROI projections tailored to your specific requirements.