Custom Rubber Extrusions: Tailored Solutions for Every Industry

Unlike standard rubber extrusions, bespoke products are designed to exact dimensions, shapes, and material specifications to ensure optimal performance for niche applications. The custom process involves selecting the best compounds for durability and environmental resistance and custom tooling and prototyping to guarantee a perfect fit and functionality. Read on to learn about the custom rubber extrusion process.

Understanding Custom Rubber Extrusions

Custom rubber extrusions differ from standard rubber extrusions as they are tailored to specific dimensions, shapes, and material requirements unique to each application. Unlike generic extrusions, they are designed to meet precise specifications for optimal performance where other pre-defined profiles don’t stack up.

Custom rubber extrusions offer higher levels of performance by aligning precisely with application needs—a tighter fit, better sealing, improved resilience under specific conditions. Their tailored structure means they withstand unique stresses, reducing the risk of wear and tear. Investing in custom extrusions can also prove more cost-effective in the long term, minimising maintenance costs and extending the lifespan of equipment and components.

Industries such as defence, automotive, aerospace, and medical benefit from this level of customisation, which meets exceptionally high performance, safety, and efficiency demands. When a crucial component of your product relies on a unique seal, profile, or tubing, a custom-made solution is the only way to ensure exacting parameters are met. This level of customisation is essential for applications requiring precise and reliable solutions.

Industries Benefiting from Custom Rubber Solutions

Custom rubber extrusions are used in myriad industries and applications. Their flexibility to produce virtually limitless designs means they can meet almost any performance requirement. Let’s take a look at the industries that use the most custom rubber extrusions.

1. Automotive Industry

1. Custom seals and gaskets: precision fit and durability are crucial for preventing leaks and ensuring optimal performance.

2. Hoses and tubing: customisation allows for specific sizes and materials that can withstand the high temperatures and pressures in automotive applications.

For example, custom gaskets for engine components must fit precisely to prevent oil and coolant leaks and ensure the engine's longevity.

Specific Requirements: In the automotive industry, custom rubber extrusions must meet rigorous standards for temperature tolerance, chemical resistance, and durability. Components such as seals and gaskets often encounter oils, fuels, and extreme heat, requiring materials with high resistance to degradation. Automotive applications demand precision in sizing and tolerance to ensure compatibility with complex assemblies. For instance, custom hoses must handle specific pressures without compromising flexibility.

2. Construction Industry

1. Weatherstripping and insulation: custom profiles ensure a perfect seal for energy efficiency and protection against the elements.

2. Expansion joints: tailored to accommodate movement and structural shifts in buildings and infrastructure.

An example is custom weather stripping for windows and doors in high-rise buildings, designed to provide an exact fit that maximises energy efficiency and protects against wind and rain infiltration.

Specific Requirements: Custom rubber solutions in construction need to be highly durable and weather-resistant, capable of withstanding prolonged exposure to UV rays, temperature fluctuations, and environmental wear. Expansion joints and weatherstripping used in buildings must be made from materials that prevent shrinkage, cracking, or warping, ensuring long-lasting seals. Additionally, fire resistance is often critical for components in certain structures, such as high-rise buildings or public spaces, to comply with safety regulations.

3. Medical Industry

1. Medical device components: custom rubber extrusions can be manufactured to meet strict regulatory standards and specific functional requirements.

2. Seals and tubing: customised for biocompatibility and sterilisation processes, essential for safe medical applications.

For example, custom rubber seals for insulin pumps must meet stringent biocompatibility standards and provide reliable, leak-proof operation for patient safety.

Specific Requirements: Medical applications demand custom rubber extrusions that comply with strict regulatory standards for biocompatibility, chemical inertness, and sterilisation. Materials must be safe for human contact and resistant to degradation by sterilisation methods such as autoclaving or chemical treatments. Tubing and sealing for devices like IV pumps or respiratory equipment must maintain flexibility and durability without leaching chemicals, ensuring patient safety and reliable performance over time.

4. Electronics Industry

1. Insulation and protective covers: custom extrusions provide precise fits to protect sensitive components from environmental damage and electrical interference.

2. Gaskets and seals: tailored to ensure the integrity and reliability of electronic enclosures.

For instance, custom rubber grommets are designed to protect cables and wires in electronic devices, ensuring they remain secure and insulated from environmental damage.

Specific Requirements: Custom rubber extrusions for electronics require precision in dimension and material selection to offer protection against electrical interference, moisture, and temperature fluctuations. They often need to meet flame-retardant and insulating standards to prevent short circuits and protect sensitive components. For instance, protective grommets for cables must be non-conductive and fit precisely to avoid abrasion or vibration damage

5. Aerospace Industry

1. Seals and gaskets: custom materials and designs that withstand extreme temperatures, pressures, and vibrations.

2. Insulation components: specialised profiles for thermal and acoustic insulation in aircraft.

An example is custom rubber seals for aircraft door frames, which must withstand extreme pressure changes and temperatures while maintaining a perfect seal for passenger safety.

Specific Requirements: Aerospace applications demand custom rubber components that can withstand extreme temperatures, pressure variations, and continuous vibrations. Materials must meet rigorous standards for thermal stability, flame resistance, and minimal outgassing. Custom seals and insulation components must maintain their integrity at high altitudes and under various flight conditions, ensuring the safety and efficiency of aircraft systems, from door seals to engine gaskets. Lightweight rubber, such as sponge rubber, is good for aerospace demands.

6. Marine Industry

1. Hull and deck seals: custom rubber extrusions provide water-tight and durable seals for various marine applications.

2. Fendering systems: tailored to specific vessel types and sizes for optimal protection against impact.

Example: custom fendering systems for yachts, providing tailored impact protection that fits the specific contours of each vessel. These systems ensure durability and performance in harsh marine environments.

Specific Requirements: In the marine industry, custom rubber extrusions must offer excellent resistance to saltwater corrosion, UV exposure, and constant movement. Seals, fendering systems, and hull components are tailored to endure the harsh marine environment without breaking down or losing elasticity. Materials are chosen for their resistance to mildew, extreme weather, and mechanical stress, ensuring that critical components remain functional in prolonged contact with water. Closed cell sponge rubber is excellent for marine applications.

7. Consumer Goods Industry

1. Appliance seals and gaskets: customised to fit unique designs and improve product longevity and efficiency.

2. Sporting goods: custom extrusions for grips, handles, and other components tailored for comfort and performance.

An example is custom door seals for refrigerators, designed to fit perfectly and enhance energy efficiency by maintaining a consistent internal temperature.

Specific Requirements: Consumer goods often require custom rubber extrusions designed for aesthetics, ergonomics, and longevity. Components like appliance seals, gaskets, and grips must fit precisely, often adhering to specific product shapes and finishes. These extrusions must also meet safety and regulatory standards, such as food-grade certification for appliances like refrigerators or easy-to-clean grips for kitchen tools.

8. Industrial Equipment and Machinery

1. Vibration dampening: custom rubber components designed to reduce vibration and noise, improving equipment lifespan and performance.

2. Seals and gaskets: tailored to handle specific chemicals, temperatures, and pressures in industrial environments.

For instance, custom rubber mounts are created for heavy machinery to reduce vibration and noise, improving operational efficiency and extending the equipment's lifespan.

Specific Requirements: Industrial environments demand rubber components capable of withstanding high mechanical stress, chemical exposure, and temperature extremes. Custom extrusions are tailored for excellent abrasion resistance and load-bearing capacity. For example, seals in hydraulic systems must handle intense pressure without degrading, while vibration-dampening components are designed to isolate shock effectively, improving the lifespan and reliability of heavy machinery.

9. Renewable Energy

1. Solar panel seals: custom extrusions provide weather-resistant and durable seals for solar panels.

2. Wind turbine components: tailored to withstand harsh environmental conditions and reduce maintenance needs.

Example: custom seals for solar panel installations that provide long-lasting weather resistance, ensuring the panels operate efficiently and are protected from moisture and dust.

Specific Requirements: Renewable energy systems, like solar panels and wind turbines, require rubber extrusions that can resist prolonged exposure to outdoor conditions, such as UV radiation, moisture, and temperature changes. Components like seals for solar panels are made to prevent moisture and dust ingress, ensuring long-term operational efficiency. Wind turbine parts must be highly durable to reduce maintenance intervals, thus lowering overall costs and improving energy yield.

10. Food and Beverage Industry

1. Seals and tubing: custom extrusions that meet food-grade standards and are designed for easy cleaning and durability.

2. Processing equipment: tailored rubber components that ensure safety and hygiene in food processing applications.

An example is custom rubber tubing for beverage dispensers, designed to meet food-grade standards and provide easy cleaning and durability, ensuring safe and hygienic operation.

Specific Requirements: Rubber extrusions for the food and beverage industry must adhere to food-grade standards, with materials that are non-toxic, odourless, and resistant to oils and bacteria. Components used in food processing, like seals and tubing, are designed for easy cleaning and sterilisation to prevent contamination. These extrusions must often be flexible yet durable enough to handle repeated sanitation cycles without compromising structural integrity.

Examples of Custom Rubber Extrusions in The Real World

Advancements in custom rubber extrusions have improved product quality, reduced waste, and bettered manufacturing efficiency, demonstrating their critical role in modern manufacturing.

Custom rubber extrusions have significantly benefited the automotive industry by improving the manufacturing of rubber profiles used in various vehicle components. A data-driven manufacturing support system was developed to enhance the quality and efficiency of rubber profiles for automotive applications. By analysing data from the extrusion process, the system helps machinists respond quickly to deviations, ensuring consistent product quality and reducing waste

In industrial applications, extrusion die design for complex-shaped rubber profiles has been optimised using finite element analysis (FEA). This approach minimises extrusion deformation, ensuring the final product meets precise specifications. The use of FEA has reduced deformation from 13% to 4%, demonstrating the effectiveness of custom die designs in producing high-quality rubber extrusions.

Custom rubber extrusions have also benefited co-extrusion processes, combining two different rubber compounds to create products with distinct hard and soft surfaces. By accurately predicting the die swell characteristics and overall deformation profiles, manufacturers can produce co-extruded rubber profiles with improved structural integrity and minimal defects. This has been validated through both experimental and computational fluid dynamics (CFD) studies, achieving an efficiency of over 98.5%.

The Process of Customising Rubber Extrusions

A watertight process ensures that the final product meets the customer's needs and expectations. At Nufox, this process is carefully managed from concept to delivery, so we know we’re meeting your requirements at every stage.

Designing and Developing a Bespoke Product

Customer Concept

The journey begins with an understanding of the customer’s objectives. Nufox works closely with customers to realise their vision.

Material Selection

Nufox’s experienced technical teams have access to a vast portfolio of tried and tested compounds developed over decades. New compounds can be formulated to meet specific project needs if required so the material used is perfectly suited to the application.

Product Route

Nufox’s state-of-the-art facilities, including extruders, presses, fabrication units, and vulcanisation methods, allow for the optimal processing of most solid rubber products. This ensures that the most efficient and effective processing method is selected for each project.

Tooling

Nufox's in-house tooling design and manufacturing capabilities, combined with its in-depth knowledge of rubber processing characteristics, facilitate rapid turnaround in tooling production. This maintains project timelines and precision to high standards.

Prototype Development

Once the processing parameters are established, a prototype is produced to achieve the correct product specifications. This step is vital for testing and refining the product before full-scale production.

Customer Approval

An agreed-upon quantity of the prototype product is provided to the customer for evaluation and feedback. This collaborative approach ensures that any necessary adjustments can be made to perfectly meet the customer's requirements.

Production

Upon approval, the product is scheduled for production. Nufox works in liaison with the customer to meet delivery requirements. All main processes are handled in-house for better control and timely supply.

Follow Up

Nufox and the customer communicate on an ongoing basis to assess the product's effectiveness. This continuous feedback loop helps improve customer support and ensures the best possible products for specific applications.

Quality Processes

Quality is paramount at every stage of custom rubber extrusion at Nufox, so we employ rigorous quality control measures to maintain high standards.

Compound Receipt

All compound suppliers undergo a thorough assessment and continuous evaluation. Upon receipt, the technical department evaluates and checks the incoming materials to ensure conformance to specifications.

Compound Testing

Extensive laboratory testing confirms compliance with customer specifications. When necessary, bespoke tests are designed to suit particular products, ensuring fitness for purpose. These tests can be conducted in-house or in conjunction with the customer.

Preparing for Production

To ensure consistency, production parameters are recorded and issued with each order. The operator confirms the correct compound and records batch numbers, ensuring full traceability.

Pre-Production Checks

Before production begins, operators check that the product is the correct size. Given the nature of rubber as an elastomer, variations can occur. Skilled operators visually inspect and adjust speeds, temperatures, and pressures to maintain tolerances, recording these adjustments for future reference.

Production

Continuous dimension checking and visual inspection are done during production to ensure quality and consistency.

Final Inspection & Packing

The final product undergoes a detailed check for dimensional accuracy, visual quality, and specific physical properties such as hardness. Various packing methods are used to meet customer requirements and ensure the product is delivered in optimal condition.

Dispatch

Customers can arrange their own transport, or Nufox can manage dispatch logistics on their behalf, ensuring the product is delivered according to the agreed-upon timeline.

Standards and Regulations

In the UK, rubber extrusions must comply with specific standards and regulations to ensure safety, quality, and suitability for various applications. Key considerations include:

1. Material Compliance:

• UK REACH: The UK Registration, Evaluation, Authorisation, and Restriction of Chemicals (REACH) regulation mandates that substances used in rubber extrusions are registered and evaluated for safety. This ensures that the materials do not pose risks to human health or the environment.

2. Industry-Specific Standards:

• Automotive Industry: Rubber components must meet standards such as ISO 11439 for high-pressure cylinders and ISO 7637 for electrical disturbances.

• Construction Industry: Compliance with BS 6213 is essential for selecting construction sealants and gaskets.

• Medical Industry: Materials should adhere to ISO 10993 for biocompatibility and BS EN 455 for medical gloves.

• Food and Beverage Industry: Rubber materials in contact with food must comply with the Food Standards Agency (FSA) regulations and be approved for food contact applications.

3. Fire Safety Regulations:

• Rubber extrusions for applications requiring flame resistance should meet standards like BS 6853 for railway applications or BS 476 for building materials.

4. Water Industry Standards:

• Rubber products used in potable water systems must have Water Regulations Advisory Scheme (WRAS) approval to ensure they do not contaminate drinking water.

5. Electrical Insulation Standards:

• Rubber extrusions used as electrical insulators should comply with standards such as BS EN 60243 for electrical strength.

6. Environmental and Health Regulations:

Compliance with the Control of Substances Hazardous to Health (COSHH) regulations is necessary to manage risks associated with hazardous materials.

Future Prospects for Custom Rubber Extrusions

Constant developments in rubber extrusion mean more innovative designs are created all the time. The ability to create bespoke extrusions means the possibilities are endless. Here are two examples of rubber extrusion projects that indicate developments for the future.

1. Automotive Industry: 3D Printing and Additive Manufacturing

Integrating 3D printing and additive manufacturing is revolutionising custom rubber extrusion in the automotive industry. This technology allows rapid prototyping and high precision production of complex, custom rubber parts. For example, manufacturers can now produce custom seals, gaskets, and hose fittings specifically designed to fit unique vehicle models, enhancing performance and reducing waste. The ability to create these parts on-demand also significantly cuts down lead times and inventory costs, leading to more efficient production processes and quicker time-to-market for new vehicle designs.

2. Construction Industry: Smart Manufacturing and IoT Integration

The construction industry is leveraging smart manufacturing and IoT integration to enhance the performance of custom rubber extrusions. Advanced sensors and real-time data monitoring allow for precise control over the extrusion process, ensuring that products meet exact specifications for high-performance building applications. For instance, custom rubber glazing systems are being developed to provide superior sealing and insulation for windows and doors, improving energy efficiency and noise reduction in buildings. The use of IoT technology ensures consistent quality and allows for predictive maintenance, reducing downtime and extending the lifespan of manufacturing equipment​.

On Sustainability

Focusing on efficiency, precision, and waste reduction are at the core of today’s eco-conscious manufacturing landscape. Unlike standard extrusion processes that may produce unnecessary surplus or generic profiles, custom rubber extrusion tailors materials to meet exact specifications. This precision minimises waste both during production and over the product's lifecycle, as custom components are built to last longer and withstand specific environmental conditions. As a result, products crafted through custom extrusion require fewer replacements, reducing raw material demand and disposal needs.

Custom rubber extrusion processes can integrate eco-friendly materials like natural or recycled rubber, which helps decrease reliance on non-renewable, petroleum-based materials. For instance, manufacturers can use bio-based polymers that offer the resilience of synthetic rubbers but degrade more easily, enhancing environmental compatibility. The ability to design rubber extrusions with end-of-life considerations in mind further supports circularity; custom extrusions can be designed for disassembly or recycling, reducing landfill waste.

In aligning with sustainability, custom rubber extrusion meets both regulatory and consumer demands for greener products, positioning businesses to contribute to a lower environmental footprint while maintaining high-quality, durable solutions across industries.

Find out about different rubber extrusion processes and which materials are best for what uses in our blog. Or take a look at all the products we can create through custom specs for you.