OMNI specializes in thermoset polymers, but more specifically High Performance Silicones and Urethanes. Over the years OMNI has developed many molding methods to produce our customers end product. These molding operations range from open cast, compression molding, spin-casting, injection molding, transfer molding, and large volume machine casting. When we were designing the complete solution we were weighing all of the possibilities as our disposal to help achieve specific objectives. Each method will be evaluated based on the criteria that was established early on. Here are a list of the more common manufacturing methods employed by OMNI.
Open casting is the most basic form of molding that OMNI utilizes. In this operation, the material is cast into an open mold that is never closed and more often than not requires a secondary machining operation to finish the part.
Compression molding is our most commonly utilized method of manufacturing. This is often due to the complexity of the parts and the simplification of the tooling to achieve a wide array of applications scaling from as few as 10-15 pieces to 200-500+ pieces. Close tolerances can be achieved with little to no post machining operations. In this operation the tooling starts out open and once dosed with the proper amount of material is closed. Under heat and pressure, the parts cure and the finished parts are removed.
Spin casting uses a closed mold where the material is dosed into a reservoir in the center of the mold. As the mold starts to spin, centrifugal force pushes the material into the cavity. This is ideal for extremely thin cross sections that require a complete bubble free part. This is also good for items that have a very complex geometry that would be difficult to by normal casting methods.
Injection molding is one of the most if not the most common form of molding. However, OMNI is slightly more unique in that we strategically look for applications that are smaller in quantity but the ideal material for the application is either machined or… Injection molded.
Transfer molding is when you start with material that is dosed and fed through a casting sprue into a closed mold. The material is often fed using air pressure or a mechanical ram. This operation utilizes many of the more common materials found in our shop, but allow for us to have some additional control to fill difficult parts.
Large Volume Machine Casting
In this operation a machine mixes, meters, and pushes the material into a mold. Based on the volume of the part will decide if this is to be a closed or open mold. We use these machines to cast parts from 5lbs cured weight to 2500+lbs of cured material. There are limitations with this process as the total number of materials available to use is limited by the equipment design.
At OMNI we pride ourselves in the quality of our work, and are committed to your overall satisfaction. Because of this unwavering commitment, OMNI worked to obtain an ISO 9001:2008 certification. After the new standard was released, we achieved and maintain a certification for ISO 9001:2015 quality standard. This is one way of ensuring our commitment to each and every customer.