Simtec integrates LSR, metal, thermoplastics production in one cell

Miramar, Fla.-based Simtec Silicone Parts LLC is starting a production process that integrates parts made of three materials — a metal, liquid silicone rubber and a thermoplastic — into one component within one manufacturing cell.

A breakthrough in LSR tooling technology enables the combination of multiple materials in a single production cell and the company is about to use it for a new application, Simtec President Enrique Camacho said in a telephone interview.

“A revolutionary approach for the integration of functions and materials is starting production at Simtec. It's the first of its kind in the world for this particular application,” Camacho said.

He said he can't identify the product or customer because of a confidentiality agreement but he could talk about the technology that is moving the company beyond overmolding LSR onto a thermoplastic substrate to also incorporating a metal part.

“We are redefining the LSR two-shot manufacturing process to LSR multi-shot,” Camacho said. “The key for us is how we combine all the elements together in such a way that it's an efficient operation with innovative solutions that push the boundaries of technology. Previously, components of a similar nature would have to go through an assembly process using extensive manual labor, necessitating multiple tools, assembly lines and large capital investments — all of which have been mitigated.”

Founded in 2002, Simtec is a research and technology-driven manufacturer with Fortune 100 companies among its customers, according to its website. Camacho opened the business in Madison, Wis., with a laser focus on LSR and a fully automated manufacturing floor. That was years before all the talk about smart factories and Industry 4.0.

“Since the inception of the company, we've been trailblazing development and adoption of production methods optimizing the interface and interactions of human beings with robotics,” Camacho said. “We're seeking to ensure consistent quality and repeatability of processes. Our company doesn't aim to reduce labor but rather to combine the skills, experience and know-how of talented team members with innovative technology.”

In 2013, Simtec moved to a larger, built-to-spec 80,000-square-foot facility in Florida, added high-precision LSR two-shot molding machines, expanded post-curing capabilities, and went on a hiring spree. The company also enhanced its quality assurance lab and shop for mold construction and maintenance. More than $8 million in new technology has been invested at the site.

Simtec now has about 50 employees who design production systems, monitor manufacturing and make sure no substandard parts or components are shipped to customers.

Camacho said Simtec is one of only a few U.S. companies to provide “true” LSR two-shot injection molding where the parts produced are ready to go and need no secondary operations. He is optimistic about the prospects for LSR multi-shot molding, which allows thermoplastics and metals to bond to LSR without complicated, time-consuming assemblies.

Like much of the plastics industry, the story of Simtec's growth is one of conversion to LSR. Camacho said the versatility of the “noble material” — biocompatibility, tolerance for extreme temperature ranges, chemical resistance and vibration absorption, to name a few — makes it ideal for broad uses and gives it potential for seemingly endless growth opportunity.

Two years after Simtec opened its doors, the company introduced LSR injected molded grommets to the U.S. auto market. Grommets reinforce the holes made to pass electrical wires, hoses, and heating and cooling ducts through a material. The customer wanted an alternative to using high-cured rubber for the product. LSR's thermal stability and durability when it comes to compression, tears and stress made it a material of choice.

“Until then customers were having issues with production, non-compliance of the parts, and the performance of the final assembly,” Camacho said. “We came up with a nice stable solution that let our partners offer a technically demanding end product at a competitive overall cost.”

Simtec saw triple-digit growth in its first few years and year-over-year growth in the double-digit range in the last few years, Camacho said. Nowadays, the majority of the business involves sanitary applications, for example shower heads, and industrial solutions, such as seals, gaskets and O-rings, which need to withstand harsh conditions as they protect components from moisture and high pressure. LSR proponents say it doesn't degrade over time; it resists steam, humidity and UV light; and it can withstand highly variable temperatures from about -60° to 570° F.

Simtec also serves life science and consumer goods customers. Not only is LSR highly biocompatible, it is transparent, hypoallergenic, inorganic, and resists bacteria and mold, which makes it good for skin contact devices, such as respirator masks, as well as flow-control valves and syringe stoppers. LSR also is flexible, withstands high heat and has a non-stick surface for bakeware and cookware uses.

Camacho said he can't divulge any details about specific products and customers that use Simtec technology, but he named some of the industry segments as baby care, grooming, transportation, safety, home entertainment, cooking and cleaning appliances and health care items. The company website says typical LSR products manufactured by Simtec include catheter tubing, lighted buttons, hand instruments, needle-free valves, pull rings and more.

Last year, Simtec became the fourth silicone company and the first in the U.S. to join a global entity called Rico Group, which purchased an unspecified number of company shares. Each business operates independently but the firms share expertise, capabilities and capacity to solve their customers' challenges.

The other companies in the group are Rico Elastomere Projecting GmbH of Austria, Silcoplast AG of Switzerland, and HTR Rosenblatti GmbH, which is a subsidiary of Rico Elastomere.

Camacho said Rico Group members have a key differentiator in the emerging LSR market with their in-house technology for tooling design, experience and pooled resources.

The business partners are competing for share in a niche market where LSR demand more than doubled from 2012 to 2015 by some accounts. Worldswide demand for LSR in 2012 was about 55,000 tons, according to one estimate. In 2015, the Rico Group's market research team put global consumption of LSR at 120,000 tons of material with an average price of $10 per kilogram.

The LSR market will grow at a compounded annual rate of 8.3 percent through 2026, when it is expected to reach $3.82 billion, according to a December 2016 news release from the research firm Markets and Markets, which has a U.S. office in Seattle. The firm says medical-grade LSR will be the fastest growing grade in the forecast period and the medical application has the largest share of the North American LSR market.

Another market report by Fractovia looks at the broader silicone elastomer and says it will hit $6.6 billion by 2023 with LSR predicted to surpass 457 kilotons by the end of 2023.