{"id":17774,"date":"2026-05-01T10:12:44","date_gmt":"2026-05-01T08:12:44","guid":{"rendered":"https:\/\/lindemannsilikon.de\/2026\/05\/01\/silikon-spritzguss-extrusion-pressformen-verfahrenswahl-2\/"},"modified":"2026-05-01T10:12:44","modified_gmt":"2026-05-01T08:12:44","slug":"silikon-spritzguss-extrusion-pressformen-verfahrenswahl-2","status":"publish","type":"post","link":"https:\/\/lindemannsilikon.de\/en\/2026\/05\/01\/silikon-spritzguss-extrusion-pressformen-verfahrenswahl-2\/","title":{"rendered":"Silicone Injection Molding vs. Extrusion vs. Compression Molding: Which Process for Which Component?"},"content":{"rendered":"\n<p><strong>Short answer:<\/strong> Three processes dominate industrial silicone manufacturing: <strong>extrusion<\/strong> for continuous profiles and silicone hoses, <strong>injection molding (LSR injection)<\/strong> for complex 3D components in medium to high volumes, and <strong>compression molding<\/strong> for large parts, mixed series, and prototype-like volumes. The choice of process follows four factors: <em>geometry, volume, tolerance requirements, and compound form (LSR vs. HTV)<\/em>. Rules of thumb: continuous 2D geometry \u2192 extrusion, micromechanics &amp; high volume \u2192 LSR injection molding, large parts\/hybrid parts\/small series \u2192 compression molding.<\/p>\n\n\n\n<p>Anyone procuring or designing silicone components should define the appropriate manufacturing process early on \u2013 otherwise, tooling costs or unit costs will increase unnecessarily. This article compares the three most important processes \u2013 <strong>extrusion, injection molding, compression molding<\/strong> \u2013 and shows how LSR (Liquid Silicone Rubber) and HTV (High Temperature Vulcanizing) affect the choice of process.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\" id=\"ueberblick\">Process overview at a glance<\/h2>\n\n\n\n<figure class=\"wp-block-table\"><table>\n<thead><tr><th>Process<\/th><th>Geometry<\/th><th>Compound<\/th><th>Tolerances (typical)<\/th><th>Cycle time \/ Output<\/th><th>Sweet Spot Volume<\/th><\/tr><\/thead>\n<tbody>\n<tr><td>Extrusion<\/td><td>Continuous 2D profiles, silicone hoses<\/td><td>HTV (solid silicone)<\/td><td>\u00b10.1 \u2013 \u00b10.3 mm (cross-section), ISO 3302-1<\/td><td>Continuous, line speed m\/min<\/td><td>linear meter, series of any size<\/td><\/tr>\n<tr><td>Injection Molding (LSR Injection)<\/td><td>Complex 3D components, undercuts, multi-component<\/td><td>LSR (liquid silicone, 2K)<\/td><td>\u00b10.02 \u2013 \u00b10.1 mm, ISO 3302-1 M1\/M2<\/td><td>30\u201360 s per shot, highly automated<\/td><td>10,000+ pieces<\/td><\/tr>\n<tr><td>Compression Molding<\/td><td>Medium to large components, simpler geometries<\/td><td>HTV (solid silicone, pre-vulcanized)<\/td><td>\u00b10.1 \u2013 \u00b10.2 mm, ISO 3302-1 M3<\/td><td>1\u20135 min per shot<\/td><td>100 \u2013 several thousand<\/td><\/tr>\n<tr><td>Transfer Molding<\/td><td>Hybrid geometry, inserts<\/td><td>HTV or LSR<\/td><td>\u00b10.05 \u2013 \u00b10.15 mm<\/td><td>1\u20133 min<\/td><td>small to medium series with inserts<\/td><\/tr>\n<\/tbody>\n<\/table><\/figure>\n\n\n\n<h2 class=\"wp-block-heading\" id=\"extrusion\">Extrusion: the process for silicone hoses and silicone profiles<\/h2>\n\n\n\n<p>In <strong>silicone extrusion<\/strong>, a pre-vulcanized HTV compound is pressed through a heated screw and a shaping die. Vulcanization then takes place directly in a continuous hot air or salt bath line. This process is the method of choice for anything with a constant cross-sectional geometry: <strong>silicone hoses, cords, hollow profiles, U-profiles, P-profiles, cellular foam profiles, co-extruded multi-component profiles<\/strong>.<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Line speed: typically 1\u201310 m\/min, depending on wall thickness and compound.<\/li>\n<li>Tooling: a die + a &#8220;mandrel&#8221; (for hollow cross-sections). Tooling costs are low compared to injection molds.<\/li>\n<li>Coextrusion: two or more compounds (e.g., soft inner core + hard outer layer) in one profile.<\/li>\n<li>Reinforcement: glass\/aramid\/polyester fabric can be incorporated in-line, e.g., for fabric-reinforced high-pressure silicone hoses.<\/li>\n<\/ul>\n\n\n\n<p>Lindemann has made extrusion a core competence and operates lines for classic and co-extruded profiles, fabric-reinforced high-pressure silicone hoses, foam profiles, and special geometries. More in <a href=\"https:\/\/lindemannsilikon.de\/silikonextrusion\/\">Silicone Extrusion<\/a> and <a href=\"https:\/\/lindemannsilikon.de\/coextrusion-von-silikonprodukten\/\">Coextrusion of Silicone Products<\/a>.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\" id=\"spritzguss\">Injection Molding (LSR Injection): Volume and Precision<\/h2>\n\n\n\n<p>In <strong>Liquid Silicone Rubber (LSR) injection molding<\/strong>, two liquid components (Component A: vinyl-functionalized polysiloxane; Component B: Si-H crosslinker with platinum catalyst) are metered in a static mixer and injected into a hot mold via a cold plasticizing unit. In the mold, the material crosslinks through hydrosilylation in seconds to a few minutes.<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li><strong>Cycle time<\/strong>: often 30\u201360 s, significantly shorter than compression molding.<\/li>\n<li><strong>Tolerances<\/strong>: \u00b10.02 mm achievable for micro-parts.<\/li>\n<li><strong>Scrap<\/strong>: minimal (cold plasticizing unit, no sprue loss with cold runners).<\/li>\n<li><strong>Multi-component capability<\/strong>: hard-soft composites (e.g., silicone adhesion to PA66, PBT, aluminum) are state of the art.<\/li>\n<li><strong>Cleanroom<\/strong>: ISO Class 7 or 8 cleanrooms are common for medical and pharmaceutical applications.<\/li>\n<\/ul>\n\n\n\n<p>The economic viability shifts in favor of LSR injection molding when component complexity is high and\/or the volume is high \u2013 tooling costs are then amortized over short cycle times. More background in <a href=\"https:\/\/lindemannsilikon.de\/spritzguss-moderne-technologie-zur-herstellung-von-silikonteilen\/\">Injection Molding \u2013 Modern Technology for the Production of Silicone Parts<\/a>.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\" id=\"pressformen\">Compression Molding: Classic for HTV<\/h2>\n\n\n\n<p>In <strong>compression molding<\/strong>, a pre-weighed HTV blank is placed in the open mold; the mold closes under pressure (typically 3\u20136 MPa) and at 150\u2013200 \u00b0C. Vulcanization takes 1\u20135 minutes, depending on wall thickness. This is often followed by <strong>post-curing<\/strong> at 200\u2013250 \u00b0C for several hours to reduce volatile components \u2013 mandatory for food and medical conformity according to BfR XV \/ FDA 21 CFR 177.2600.<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Tooling costs lower than injection molding, often the economical choice up to approx. 5,000 pieces\/year.<\/li>\n<li>Very good for <strong>large components<\/strong>, wall thicknesses over 10 mm, and components with inserted inserts.<\/li>\n<li>Tolerances slightly wider than injection molding (\u00b10.1\u20130.2 mm), but sufficient for many industrial applications.<\/li>\n<li>Higher scrap (flash) than LSR injection molding; post-processing (cryogenic deflashing) is part of the process.<\/li>\n<\/ul>\n\n\n\n<h2 class=\"wp-block-heading\" id=\"lsr-vs-htv\">LSR vs. HTV: what does this mean for process selection?<\/h2>\n\n\n\n<p>The compound form indirectly determines the process. <strong>HTV<\/strong> (high-molecular polysiloxane, typically 400,000\u2013800,000 g\/mol molecular weight) is a &#8220;solid silicone&#8221; and is processed in extrusion and compression molding. <strong>LSR<\/strong> is a liquid, low-viscosity system (10,000\u201380,000 g\/mol polymer base) and is typically used in 2K injection molding.<\/p>\n\n\n\n<figure class=\"wp-block-table\"><table>\n<thead><tr><th>Property<\/th><th>HTV<\/th><th>LSR<\/th><\/tr><\/thead>\n<tbody>\n<tr><td>Form<\/td><td>Solid, kneadable compound<\/td><td>Two liquid components (A+B)<\/td><\/tr>\n<tr><td>Crosslinking<\/td><td>Peroxidic or additive (Pt)<\/td><td>Additive (Pt-catalyzed)<\/td><\/tr><\/tr>\n<tr><td>Mechanical Strength<\/td><td>Tends to be higher, higher tear strength<\/td><td>Very high reproducibility, smaller tolerances<\/td><\/tr>\n<tr><td>Main Process<\/td><td>Extrusion, Compression Molding<\/td><td>Injection Molding (LSR Injection)<\/td><\/tr>\n<tr><td>Purity<\/td><td>Post-curing often necessary (peroxidic)<\/td><td>High, Pt-crosslinking without volatile by-products<\/td><\/tr>\n<tr><td>Tooling Costs<\/td><td>Rather low (Compression Molding) \/ medium (Extrusion)<\/td><td>High (Multi-component, hot runners, cold runner)<\/td><\/tr>\n<\/tbody>\n<\/table><\/figure>\n\n\n\n<p>A detailed discussion of the compound families: <a href=\"https:\/\/lindemannsilikon.de\/htv-lsr-rtv-silikon-untersch\/\">Differences HTV, LSR, and RTV Silicone<\/a>.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\" id=\"entscheidung\">Decision Matrix: Which process to choose?<\/h2>\n\n\n\n<ol class=\"wp-block-list\">\n<li><strong>Does the component have a continuous cross-section<\/strong> (silicone hose, silicone profile, cord)? \u2192 <strong>Extrusion<\/strong>, possibly co-extruded. Volume plays a minor role, as tooling costs are low.<\/li>\n<li><strong>Complex 3D geometry + high volume + tight tolerances?<\/strong> \u2192 <strong>LSR injection molding<\/strong>. Tooling investment pays off through cycle time.<\/li>\n<li><strong>Larger components, simple geometry, medium volume, inserts?<\/strong> \u2192 <strong>Compression molding<\/strong>. Lower tooling costs, acceptable tolerances.<\/li>\n<li><strong>Hybrid part with metal\/plastic inserts and medium volume?<\/strong> \u2192 <strong>Transfer Molding<\/strong> as a compromise between compression molding and injection molding.<\/li>\n<\/ol>\n\n\n\n<h2 class=\"wp-block-heading\" id=\"kosten\">Where the costs really hide<\/h2>\n\n\n\n<p>Empirical values from plant and equipment construction:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li><strong>Tooling costs<\/strong>: Extrusion &lt; Compression Molding &lt; Injection Molding. A 2K injection mold for complex geometry can quickly cost many times more than a compression mold.<\/li>\n<li><strong>Unit costs<\/strong>: for medium to high volumes, the picture reverses \u2013 LSR injection molding is then usually the cheapest option.<\/li>\n<li><strong>Post-processing<\/strong>: LSR injection molding often requires no deflashing, compression molded parts almost always do. Extruded profiles are cut to length or welded.<\/li>\n<li><strong>Compound choice<\/strong>: High-temperature, food-grade, pharmaceutical, and flame-retardant compounds are 2\u20135 times more expensive than standard compounds. Often underestimated in unit cost calculations.<\/li>\n<\/ul>\n\n\n\n<h2 class=\"wp-block-heading\" id=\"zulassungen\">Process and Approval<\/h2>\n\n\n\n<p>All three processes deliver components that can be certified according to <strong>BfR XV, FDA 21 CFR 177.2600, USP &lt;87&gt;\/&lt;88&gt; Class VI<\/strong> or <strong>ISO 10993<\/strong> \u2013 provided the chosen compound is approved and the component is post-cured if necessary. Cleanroom manufacturing is most directly achievable in injection molding (closed process), and possible in extrusion and compression molding with greater effort.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\" id=\"faq\">FAQ: Process selection for silicone<\/h2>\n\n\n\n<h3 class=\"wp-block-heading\">Why does an LSR mold cost so much more than a compression mold?<\/h3>\n\n\n<p>Because LSR molds require high-precision hot\/cold runner systems and tight tolerances, often with interchangeable inserts for 2K processing. Compression molds can manage with simpler mechanics.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\">At what volume does injection molding become worthwhile?<\/h3>\n\n\n<p>A rule of thumb: from about <strong>10,000 pieces\/year<\/strong>, LSR injection molding becomes more economical than compression molding, often even earlier for complex geometries and tight tolerances. A reliable answer can only be provided by a specific calculation.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\">Which process is most economical for silicone hoses?<\/h3>\n\n\n<p>Extrusion \u2013 without exception. Manufacturing silicone hoses by injection molding would be uneconomical, as silicone hoses by definition have a continuous geometry.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\">Can metal inserts (e.g., threaded bushings) be molded in?<\/h3>\n\n\n<p>Yes, both in compression molding (classic, insert is placed before vulcanization) and in LSR injection molding (with core pins and insertion robotics). Adhesion is achieved via primers or self-adhesive LSR compounds.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\">What is the difference between compression molding and transfer molding?<\/h3>\n\n\n<p>In compression molding, a blank is placed directly into the cavity and pressed by closing. In transfer molding, the compound is &#8220;pressed&#8221; from a pre-chamber into the cavity. Advantages: better tolerances, less flash, good for inserts. Disadvantages: higher tooling costs than pure compression molding.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\">Which process is suitable for cleanroom applications?<\/h3>\n\n\n<p>LSR injection molding is a closed, automated process and therefore ideal for cleanroom manufacturing (ISO 7\/8). Compression molding and extrusion are also possible in appropriately designed lines, with higher organizational effort.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\" id=\"quellen\">Sources<\/h2>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Elkem Silicones: <a href=\"https:\/\/magazine.elkem.com\/material-science-insights\/different-processing-methods\/\" rel=\"noopener\" target=\"_blank\">Different processing methods for silicone rubber<\/a>.<\/li>\n<li>Cabot Corporation: Silicone Rubbers (HTV &amp; LSR) \u2013 Material and Process Background.<\/li>\n<li>ISO 3302-1: Tolerances for molded elastomer parts.<\/li>\n<li>ISO 23529: General procedures for preparing and conditioning elastomer samples.<\/li>\n<li>Shin-Etsu Silicones: Technical data \u2013 LSR and HTV Compound Families.<\/li>\n<li>BfR Recommendation XV &#8220;Silicones&#8221;; FDA 21 CFR 177.2600 \u2013 see linked articles on this page.<\/li>\n<\/ul>\n\n\n<script type=\"application\/ld+json\">\n{\n  \"@context\": \"https:\/\/schema.org\",\n  \"@graph\": [\n    {\n      \"@type\": \"Article\",\n      \"headline\": \"Silicone Injection Molding vs. Extrusion vs. Compression Molding: Which Process for Which Component?\",\n      \"description\": \"The three most important silicone manufacturing processes in a decision matrix: Extrusion, LSR Injection Molding, Compression Molding. 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Tolerances, quantities, tooling and unit costs \u2013 and when LSR vs. HTV makes sense.<\/p>\n","protected":false},"author":8,"featured_media":17750,"comment_status":"","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"_yoast_wpseo_focuskw":"","_yoast_wpseo_title":"","_yoast_wpseo_metadesc":"","_yoast_wpseo_canonical":"","_yoast_wpseo_opengraph-title":"","_yoast_wpseo_opengraph-description":"","_yoast_wpseo_opengraph-image":"","_yoast_wpseo_twitter-title":"","_yoast_wpseo_twitter-description":"","_yoast_wpseo_twitter-image":"","footnotes":""},"categories":[2,79],"tags":[],"class_list":["post-17774","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-news","category-silikonprodukte","category-2","category-79","description-off"],"yoast_head":"<!-- This site is optimized with the Yoast SEO Premium plugin v26.4 (Yoast SEO v27.5) - https:\/\/yoast.com\/product\/yoast-seo-premium-wordpress\/ -->\n<title>Silicone Injection Molding vs. Extrusion vs. Compression Molding: Which Process for Which Component? - Lindemann Silikon<\/title>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/lindemannsilikon.de\/2026\/05\/01\/silikon-spritzguss-extrusion-pressformen-verfahrenswahl-2\/\" \/>\n<meta property=\"og:locale\" content=\"en_US\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"Silicone Injection Molding vs. Extrusion vs. Compression Molding: Which Process for Which Component?\" \/>\n<meta property=\"og:description\" content=\"The three most important silicone manufacturing processes in a practical decision matrix: Extrusion for profiles and hoses, LSR injection molding for complex 3D components, compression molding for large parts and medium series. 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