Silicone rubber compounds are versatile materials used across industries for their durability, flexibility, and resistance to extreme environments. These compounds are critical in automotive, medical, electrical, and food-grade applications, from high-performance rubber silicone components to FDA-compliant silicone products. Leading manufacturers like Elastostar Rubber Corporation specialize in custom rubber gaskets and extrusions customised to meet demanding specifications.
In this blog, we’ll explore the meaning of silicone rubber compounds, their properties, various types, manufacturing processes, and real-world applications across industries, giving you a complete understanding of this indispensable material.
Understanding Silicone Rubber at Its Core
The chemical composition of silicone, a combination of silicon, oxygen, carbon, and hydrogen, gives it exceptional flexibility, thermal stability, and resistance to moisture and chemicals. These properties make it ideal for products such as silicone sheets, sponge tubes, and extruded rubber profiles used in demanding environments.
When comparing silicone vs silicone rubber, the terms are often used interchangeably. However, silicone refers to the raw polymer, while the cured version is used in seals, gaskets, and insulation products. Deciding between silicone or rubber depends on factors like temperature resistance, electrical insulation needs, and exposure to harsh conditions.
Read More – What is FDA Silicone Made Of?
History & Evolution of Silicone Rubber Seals
Silicone-based materials first emerged in the early 20th century as a response to the need for flexible compounds that could endure extreme temperatures and environmental exposure. Over the decades, the material evolved into a core component across industries, significantly as demand grew for reliable alternatives to natural and synthetic rubber.
Today, custom silicone products like seals, gaskets, and silicone sponge profiles are widely used in aerospace, automotive, pharmaceutical, and food-grade applications.
As a leading custom rubber product manufacturer, Elastostar has supported this evolution by offering high-performance components designed for consistency, durability, and long-term use across demanding environments.
Read More – Silicone Rubber: Where It Comes From
What are the Types & Grades of Silicone Rubber Compounds?
Silicone compounds are produced in various forms to support different functions across industries. Each type offers distinct characteristics regarding texture, density, and performance.
- Silicone sponge is a closed-cell material known for its compressibility, lightweight nature, and excellent resistance to temperature extremes. For applications requiring medium to firm density, Elastostar offers a range of products such as the AMS3195 Medium Silicone Sponge and AMS3196 Firm Density Silicone Sponge, ideal for sealing, insulation, and gasketing.
- FDA-approved rubber is developed explicitly for environments involving direct contact with food. Elastostar’s Solid FDA Grade White Silicone meets regulatory standards for processing and packaging equipment, ensuring safety without compromising performance.
- Custom silicone gaskets are used in demanding applications requiring heat, chemicals, and environmental exposure resistance. These gaskets are found in industrial enclosures, HVAC systems, and lighting assemblies, where consistent sealing is critical.
Each grade serves a specific purpose, providing engineers and manufacturers with options that meet technical and compliance requirements for various industries.
Additional Types & Grades of Silicone Rubber Gaskets
| Type / Grade | Key Features | Common Uses |
| Solid Silicone Rubber (HCR) | Dense, non-porous, heat-resistant | Extrusions, molded parts |
| Liquid Silicone Rubber (LSR) | Flowable, suitable for injection molding | Complex parts, medical devices |
| RTV Silicone | Cures at room temperature, available in 1-part or 2-part systems | Adhesives, sealants, coatings |
| Fluorosilicone Rubber | Excellent fuel and oil resistance | Aerospace, automotive |
| Medical Grade Silicone | Biocompatible, sterilizable | Tubing, implants, surgical components |
| Electrically Conductive Silicone | Shields EMI/RFI, or offers electrical insulation | Electronics, electrical enclosures |
| High Temperature Silicone (HTV) | handles high heat (up to 250°C+) | Oven seals, engine gaskets |
| Shields EMI/RFI or offers electrical insulation | Maintains shape under long-term pressure | O-rings, gaskets |
What are the Properties of Silicone Rubber Compounds?
Silicone seal materials offer various performance characteristics that differentiate them from other elastomers.
- Excellent Temperature Resistance
Performs reliably across a wide temperature range, typically from -60°C to 230°C, without losing flexibility or strength. - Outstanding Weathering & UV Resistance
Tolerates ozone, sunlight, and outdoor exposure over time for exterior use. - Electrical & Silicone Insulation
Silicone’s high dielectric strength makes it ideal for electrical components. Its consistent silicone insulation performance helps protect against voltage fluctuations. - Chemical Stability
Resistant to water, oils, solvents, and many chemicals, even under prolonged exposure. - Low Thermal Conductivity
Silicone’s naturally low thermal conductivity makes it a good insulator in thermal management systems. Electrically conductive silicone is also used to shield electromagnetic interference (EMI) or provide electrical insulation in various electronic applications. - Compression Set Resistance
It maintains its shape and sealing ability under pressure, which is ideal for gaskets and seals. - Flexibility & Elasticity
A core property of rubber, especially in silicone compounds, is its ability to stretch and recover without permanent deformation.
These properties make silicone-based materials suitable for high-performance sealing, insulating, and vibration-damping applications across various industries.
What are the Advantages of Silicone Rubber Compounds?
Silicone tube-based materials provide a range of high-performance benefits, demanding industrial and commercial applications.
- Excellent Thermal Stability
It performs effectively across a broad temperature range, far exceeding the rubber melting temperature, for environments involving heat exposure. - Weather & UV Resistance
Maintains integrity when exposed to sunlight, ozone, and outdoor conditions ideal for exterior and long-term use. - Electrical Insulation
Conductive rubber is known for its strong dielectric properties; it provides reliable electrical and electronic protection. - Non-Reactive & Safe
Used in medical, food-grade, and cleanroom environments due to its inert, non-toxic nature. - Consistent Performance
Unlike organic rubbers, silicone retains its flexibility and durability across its service life. - High Heat Resistance Compared to Natural Rubber
Outperforms materials with a lower melting temperature of natural rubber, especially in industrial sealing and gasketing.
Read More – High Temperature Grades of Rubber
How is Silicone rubber made? The Manufacturing Process
The production of silicone-based materials follows a structured process: performance, consistency, and reliability.
| Step | Process Description |
| 1. Material Selection | Selection of base polymers and additives defines the rubber compound formula, including any colorants, flame retardants, or reinforcements. |
| 2. Mixing & Compounding | Ingredients are blended to ensure uniform chemical and physical properties, preparing the compound for further processing. |
| 3. Shaping & Extrusion | Precision machinery forms the material into continuous shapes such as silicone tubing, seals, and rubber extrusion profiles. |
| 4. Curing (Vulcanization) | Heat and pressure are applied to crosslink the material, enhancing its elasticity and mechanical strength. |
| 5. Cutting & Finishing | Extruded parts are trimmed to size, cleaned, and prepared for final inspection. |
| 6. Quality Control | Precision machinery forms the material into continuous shapes such as tubing, seals, and rubber extrusion profiles. |
This process ensures each product meets industry-specific demands for insulation, sealing, or high-temperature applications.
What Are the 7 Key Applications of Silicone-Based Materials by Industry?
Due to their durability, thermal stability, and chemical resistance, silicone-based compounds are essential across various industries.
1. Automotive and Transportation
- Components such as hoses, seals, and thermal shields are used in powertrain and under-hood automotive systems.
- Silicone rubber gaskets offer long-term resistance to heat, oils, and vibration, maintaining consistent sealing performance.
2. Medical and Healthcare
- Used in tubing, closures, and gaskets for devices that require sterility and biocompatibility.
- Suitable for regulated environments that demand clean, non-reactive materials.
3. Industrial Equipment and Machinery
- Rubber seal extrusion is applied in enclosures, machinery panels, and sealing systems.
- Offers protection against dust, moisture, and mechanical pressure in industrial settings.
4. Construction and HVAC
- Used in structural expansion joints, weather seals, and flexible connectors in construction industry and HVAC industry.
- Handles temperature fluctuations and UV exposure in both indoor and outdoor environments.
5. Electronics and Electrical
- Provides insulation, moisture sealing, and stability in electrical housings and connectors.
- Maintains performance under voltage stress and thermal variation.
6. Food and Beverage Processing
- FDA-compliant silicone is used for seals, tubing, and contact surfaces.
- Ensures hygiene and safety in food handling and food processing equipment.
7. Consumer and Specialty Products
- Found in wearables and electronics.
- Custom silicone rings and molded components combine flexibility with reliable, long-term use.
Manufacturing and Supply Support
Elastostar, a leading rubber gasket manufacturer, supports these industries with consistent, high-performance materials. The company delivers reliable solutions across sectors, from rubber seal extrusion to high-purity silicone grades.
Sustainability & Recycling of Silicone-Based Materials
Silicone seals are valued for their long lifespan, which supports sustainability by reducing material waste and replacements. While not biodegradable, silicone rubber can be recycled through specialized processes, allowing it to be reused in non-critical applications.
Unlike materials with a lower natural rubber melting temperature, silicone tubes maintain performance under extreme heat, contributing to durability and fewer failures.
Its use in long-lasting rubber profiles and seals further supports efficient resource use, especially in industrial and high-demand environments.
Partnering with Elastostar: Excellence in Silicone Innovation
At Elastostar Rubber Corporation, we stand out among leading silicone rubber extrusion manufacturers, delivering precision solutions for demanding industrial applications. We support full project cycles—from reverse engineering and design assistance to prototype through production runs with good performance, reliability, and efficiency at every stage.
With advanced extrusion capabilities and ISO-certified processes, we maintain consistent quality across various custom profiles, seals, and gaskets. Known for our responsiveness and flexibility, we offer some of the shortest lead times in the industry.
Whether you operate in the industrial, medical, food-grade, or aerospace sectors, we combine technical expertise with dependable service to be your trusted partner for custom silicone components.
Contact us today to discuss your project or request a quote—our team is ready to assist you.
Recommended Reads
- Why FDA-Approved Silicone Rubber Is Preferred for Food Industry Gaskets & Seals
- Top Benefits of Using Silicone Rubber in the Aerospace Industry
- How to Select the Right Silicone O-Rings for Industrial Applications
Conclusion
Silicone rubber compounds perform well in extreme temperatures, chemical exposure, and demanding environments. Their versatility makes them ideal for applications across the medical, automotive, food, and industrial sectors. Understanding their types and properties, from sponge profiles to FDA-grade silicone and high-temperature formulations, helps ensure the right material is selected for each use.
At Elastostar Rubber Corporation, we specialize in manufacturing precision silicone components—custom gaskets, rubber profiles, and extrusion solutions designed to meet stringent industry standards. With expert engineering support and consistent quality, we’re committed to helping you achieve reliable, long-lasting results for any silicone rubber application.
FAQs
What is the melting temperature of silicone?
Silicone does not melt like traditional thermoplastics. Instead, it retains its structure up to approximately 250°C (482°F) and begins to degrade at higher temperatures, depending on the formulation.
What is silicone rubber used for?
Silicone rubber is used in gaskets, seals, tubing, medical devices, electrical insulation, kitchenware, and more. Elastostar, a trusted silicone rubber gasket manufacturer, offers various components for industrial and commercial use.
Is silicone a rubber or plastic?
Silicone is a rubber, not a plastic. It is a synthetic elastomer made from silicon and oxygen atoms, known for its flexibility, durability, and excellent thermal and chemical resistance.
Why is silicone rubber so expensive?
Silicone rubber cord is more expensive than other elastomers due to its complex manufacturing process, high-purity raw materials, and superior performance characteristics. Elastostar uses only high-grade silicone in its products to ensure long-term value.
How long does silicone rubber last?
Silicone seals are known for their exceptional longevity, often lasting 10 to 20 years or more, depending on the application and environment. For long-life sealing solutions, explore Elastostar’s custom rubber products.
Is silicone rubber bad for the environment?
Silicone rubber is not biodegradable but is non-toxic and chemically stable, so it doesn’t leach harmful substances into the environment. For eco-conscious product options, reach out to Elastostar to learn more.
