Custom silicone cut pieces – practical guide

Custom silicone cut formats – practical guide

Custom silicone cut formats are a solution that is increasingly replacing ready-made, universal sealing and insulating components. Thanks to the possibility of precise adaptation to a device, process, or structure, silicone formats ensure higher durability, operational stability, and safety. In this article, you will find reliable, practical information: what silicone formats are, their properties, where they are used, and how to properly prepare an order.

What are custom silicone formats?

Custom silicone formats are elements cut from silicone sheets, mats, or strips according to individual customer specifications. They can take the form of:

• flat plates and sheets

• strips of a defined width

• pads and gaskets

• elements of irregular shapes cut from CAD files

Unlike catalog products, silicone formats are manufactured exactly to the required dimensions, thickness, and hardness, which allows their use in applications where standard solutions are insufficient.

Key properties of silicone determining its applications

Temperature resistance

Silicone maintains stability over a wide temperature range — from approx. −50°C to +200°C (and special compounds even more). Therefore, silicone formats are suitable for:

• ovens and heating tunnels

• cooling and freezing equipment

• machines operating in heating and cooling cycles

Elasticity and resilience

Silicone does not lose elasticity at low or high temperatures. This is crucial for:

• seals requiring surface conformity

• vibration damping

• compensation of minor structural deformations

Material hardness is selected on the Shore A scale — most commonly 40–70 ShA.

Chemical and ageing resistance

Silicone is resistant to:

• oils and greases

• weather conditions, UV, and ozone

• thermal ageing

As a result, silicone formats remain durable even during long-term exposure to demanding conditions.

Safety in contact with food

Silicone compounds compliant with food contact standards (e.g., FDA) are available. This is essential in industries where hygiene and safety are critical.

Applications of custom silicone formats

Food industry

• silicone mats on work tables and conveyors

• seals for oven doors and chambers

• silicone belts in heating and cooling tunnels

Requirements:

• temperature resistance

• ease of cleaning

• food contact certifications

Mechanical engineering and automation

• gaskets and pads cut from silicone sheets

• insulating elements in enclosures and control cabinets

• anti-vibration pads

Requirements:

• dimensional repeatability

• mechanical stability

• resistance to environmental conditions

Chemical and laboratory industry

• silicone mats resistant to chemicals

• seals in process equipment

Requirements:

• chemical resistance

• long-term operational stability

Specialized production and prototyping

Custom silicone formats are also used in individual projects where unusual shape, precise fit, or specific material properties are required.

Silicone cutting process

1. Requirements analysis

At the beginning, the following are defined:

• dimensions and tolerances

• operating temperature range

• environment (humidity, oils, chemicals, UV)

• standard requirements (e.g., food contact)

• quantity and delivery mode

The more precise the data, the better the material selection.

2. Material selection

The manufacturer selects:

• type of silicone compound

• Shore A hardness

• sheet thickness

• color (optional)

3. Cutting technology

Depending on the project, the following are used:

• CNC / plotter cutting — highest precision, ideal for complex shapes

• die cutting — cost-effective for larger series

• band cutting — for strips and simple formats

4. Quality control

Finished formats are measured and verified for compliance with the design. If required, the manufacturer provides declarations of conformity and material documentation.

How to prepare a proper inquiry?

To receive an accurate quotation, provide:

• Dimensions – length, width, thickness, tolerances

• Shape – description, technical drawing, or CAD file

• Hardness – e.g., 50 ShA (or operating conditions if unknown)

• Temperature range – continuous and peak

• Working environment – oils, steam, UV, food

• Standard requirements – e.g., FDA, fire resistance

• Quantity – prototype, series, recurring deliveries

• Lead time – standard or expedited

Common mistakes when ordering silicone formats

• providing approximate instead of precise dimensions

• lack of information about operating temperature

• not specifying hardness or standard requirements

• omitting working environment (e.g., contact with oils)

• sending incomplete drawings or sketches

Avoiding these mistakes shortens lead time and reduces the risk of errors.

Custom silicone formats available at Power Rubber

What dimensions of silicone formats can be ordered?

From a few centimeters up to sizes corresponding to base sheet dimensions. For very large elements, joining or special solutions are used.

Are silicone formats suitable for food contact?

Yes, if made from a compound with appropriate certifications. It should be specified in the inquiry.

Can single pieces be ordered?

Yes. Most manufacturers produce both prototypes and production series.

How long do silicone formats last?

With proper compound selection and operating conditions — even several years of intensive use.

Contact Power Rubber

If you need silicone formats perfectly matched to your process, device, or project — contact us. We will advise on the appropriate material, prepare a quotation, and manufacture custom formats with the highest precision.

Contact us by phone at +48 22 292 40 24 or +48 505 16 03 03, by email (Power@PowerRubber.com), or via our contact form.

Power Rubber – professional silicone products for industry.