4 Reasons to Use Nomex® for Fabric-Reinforced Diaphragms
At Micro-Tronics, we believe in precision from start to finish and deliver top-quality parts built to our customers’ stringent specifications. One highly specialized and niche offering we provide is producing fabric-reinforced elastomer diaphragms.
Fabric-reinforced diaphragms ensure the proper transfer of fluid or air. They are carefully designed and constructed barriers that separate one chamber from another in fluid or pneumatic systems (e.g., valves, pumps, meters, regulators, and other control devices).
Superior parts require premium materials, which is why we use Nomex® to build fabric-reinforced diaphragms for our customers in the aerospace industry.
This flat diaphragm has a small convolute (the orange ridge encircling the metal part).
This deep draw diaphragm has a relatively high aspect ratio between diameter and depth. Note it is wrinkle-free and smooth, without any tears.
Nomex® is a High-Performance Material for Top-Quality Parts
Are you new to Nomex®? Made by Dupont, Nomex® is a meta-aramid fiber highly suited for applications across the aerospace, automobile, military, and defense industries, as well as first-responder uniforms and protective gear.
The proprietary chemical structure of Nomex® fibers delivers heat and flame protection, chemical resistance, electrical insulation, and incredible durability. Because Nomex® is a lightweight material that’s flame and corrosion resistant, it’s an ideal choice for our aerospace customers.
Let’s look closer at 4 reasons why you’ll want Nomex® for your fabric-reinforced diaphragms.
4 Reasons to use Nomex® for Fabric-Reinforced Diaphragms
1. Versatility.
Nomex® is leveraged across industries to build coated industrial fabrics, aerospace fabrics, electrical insulation, hot-gas filter bags, protective clothing, and high-temperature hoses. Most of the diaphragms we make are used in pneumatic control valves in aerospace applications.
2. Heat and cold resistance.
Fabrics woven with Nomex® fibers have low flammability levels and don’t melt at high temperatures. While the material might look like nylon, nylon will melt at 489 degrees Fahrenheit—at which point Nomex® still has 60% of its original strength. Nomex® can tolerate temperatures up to an incredible 700 degrees Fahrenheit, and it can withstand extremely low temperatures, too. Nomex®’s heat and cold resistance are ideal for aerospace applications that must withstand extreme heat and cold.
3. Chemical resistance.
Parts made with Nomex® can stand up to most hydrocarbons and many other organic solvents. Nomex® also has acid resistant properties superior to those in woven nylon fabrics, and its fibers exhibit good resistance to alkalis at room temperature (though they do degrade at high temperatures).
4. Radiation resistance.
Nomex® can resist damage from X-rays and beta and gamma radiation much more successfully than a fabric like nylon.
If you’re creating a highly engineered, top-of-the-line, premium fabric-reinforced diaphragm, Nomex® is the material you need. It’s highly durable and genuinely the best choice for applications requiring heat, chemical, radiation resistance, and high strength.
Our team of experts can manufacture your high performance Nomex diaphragm. We deliver precision, high-quality parts on time and at a fair price. To get started making your fabric-reinforced diaphragms, request a quote today.
EDM is a non-contact machining method that creates an electrical current between a conductive workpiece and an electrically charged shape or wire composed of a brass, copper, graphite, or tungsten alloy. The spark generated by the electrical current erodes the material, and a non-conductive fluid, such as deionized water or oil, washes away any waste.
EDM first took off in the 1940s and gained popularity in the 1960s as capabilities increased. Still, most engineers are more familiar with CNC machining and consider EDM a non-conventional manufacturing process. EDM has a reputation for being slower and more expensive than CNC machining.
However, EDM manufacturing has advanced significantly in recent years, improving cost and efficiency and minimizing recast issues that were previously a concern.
What makes a project a good candidate for EDM services? Here’s everything you need to know.
Top 4 Factors for Choosing EDM
1. Geometric requirements
With EDM, it’s possible to cut precision keyways, hexes, internal splines, shaft pockets and slots, and other unique features without making custom (i.e., expensive and time-consuming) broaches. There are times when only EDM can produce the specific, complex geometric shapes that a part requires.
Need to cut through curved or angled surfaces? No problem—EDM can navigate virtually any contour, and Micro-Tronics’ talented team members manage varying tapers with exceptional precision. EDM can also handle fragile and thin sections because the wire electrodes never actually contact the workpiece.
2. Hardened materials
EDM is an excellent choice when making parts from very hard materials such as tool steel.
These materials are difficult to cut using traditional machining methods. They cause significant tooling wear, yielding low-accuracy results and rough finishes.
Since EDM uses electrical current, the risks of tooling wear is eliminated entirely. It’s possible to cut through many hard, conductive materials with precision, ease, and speed.
3. Delicate features and fine finishes
Intricate designs are easier to render with EDM manufacturing than CNC machining. If your project has delicate features, EDM’s non-contact process eliminates cutting stress and mechanical distortion, resulting in a superior quality part.
EDM also produces exceptional finish quality. Mirror-like finishes are possible with this process, and with no secondary polishing operations required, customers can save time and money.
4. Quick turnaround
EDM is a great choice if time is of the essence. Since it’s usually a toolless solution requiring minimal setup and programming, we can get your project up and running quickly.
At Micro-Tronics, we’ll also help you optimize lead times with quick quoting and leverage our in-house tool room for rapid specialty fixturing and electrodes.
Now that you know the benefits and capabilities of EDM manufacturing, it’s essential to understand the types of EDM services available.
The 3 Types of EDM Services
1. Wire EDM
In wire EDM, the electrode is brass wire. Think of it as a “super-precision band saw” that can make through-hole parts. Wire EDM is consistently reliable and can produce burr-free, perfectly straight parts. While a traditional drill can drift, wire EDM doesn’t waver. It’s a great alternative to broaching for short timelines or small-to-medium volume runs.
At Micro-Tronics, we pride ourselves on our rotary wire EDM services. We can make a wide variety of precise, complex shapes—economically and efficiently—through the “turn and burn” technique. We use the same machine to burn one side of the workpiece, then turn it and burn the next side without changing out the workpiece. This streamlined process saves our customers time and money.
2. Sinker EDM
Sinker EDM traditionally uses a graphite or copper electrode. The electrode itself is made into a specific shape which is then burned into the workpiece to create the part.
Primarily used to produce blind cavities, Sinker EDM can create internal splines and keyways with no through-holes.
Sinker EDM is the solution when the job requires sharp corners, intricate details, fine finishes, and the machining of undercut surfaces. It’s also ideal for hardened materials, and its non-contact method combined with low-pressure flushing makes it perfect for thin and delicate parts.
3. Small hole EDM
If your part requires a deep, tiny hole, you’ll need small hole EDM services. Small hole EDM can manage minuscule diameters (.007” – .25”) and achieve high aspect ratios while cutting perfectly straight into the workpiece. Meeting these dimensional requirements would likely cause CNC machining tools to break or shatter.
Small hole EDM is fast, accurate, and can handle curves and angles. Small hole EDM also eliminates the need to deburr drilled holes post-machining.
What About Recast?
One last EDM consideration is the issue of recast. If you’ve used EDM services in the past, you may have run into this problem.
Recast is a thin layer of molten material that can land on top of the workpiece when sparks create a heat-affected zone. It’s undesirable and can make the surface brittle.
Working with an expert EDM manufacturer will mitigate this issue. At Micro-Tronics, our state-of-the-art anti-electrolysis power supplies and manufacturing techniques can reduce the recast layer to as little as 2.5μm(0.000098”): essentially zero. We remove the recast layer with processes like extrude honing, lapping, and electropolishing—leaving no cracks.
EDM is a great option when projects require delicate details, complex geometric shapes, and tiny, deep holes. If you’re curious about using EDM for your part, we’re happy to help you identify the process that’s best for your project.
We have 50+ years of experience delivering large quantities of EDM manufactured products—we’d be thrilled to partner with you on yours. To get started, request a quote today.
Elastomer products are everywhere in our modern lives—from the soles of our shoes to the critical sealing surfaces on the aircraft you fly on, elastomers (sometimes referred to as rubber) make the world go round.
But despite the prevalence of this viscoelastic polymer, information about it is difficult to find. There are many elastomers to choose from—each with unique properties and price points—which complicates matters even further. Engineers who are new to designing elastomer products may have a hard time making an informed decision about which elastomer to use.
For instance, if you’re designing a component for an aircraft that flies through sub-zero temperatures but also sits on hot tarmacs in the sun, you’ll need an elastomer for your custom molded rubber seals that can withstand extreme temperatures. If you’re designing a part for a fuel or hydraulic system, you’ll need an oil and fuel resistant elastomer.
Even material stiffness varies significantly. Elastomer materials can be stiff and strong like bowling balls, while others are soft and flexible, with a texture more like chewing gum.
To help make material selection easier, our team of experts at Micro-Tronics created a resource guide spotlighting 20 common elastomers. Learn the thermal properties, environmental and fluid resistances, and tensile strengths of each one.
Elastomer Spotlight: Silicone, Nitrile, and Fluoroelastomer
Silicone: Taking on Extreme Temperatures
If you’re designing a rubber part that will need to withstand extreme temperatures, silicone could be the best option. With a temperature range spanning -120 to 500 degrees Fahrenheit, silicone is great for aerospace parts and transportation vehicles that most function in intense climates.
Silicone has outstanding environmental and water resistant properties, and it’s capable of sustaining exposure to UV rays and inclement weather. This material can even handle deep sub-zero temperatures without becoming brittle and breaking. But if you’re on a tight budget, know that silicone isn’t the cheapest option.
Nitrile: Outstanding Oil, Fluid, and Wear Resistance
If you’re familiar with elastomers, you might know nitrile as NBR or Buna N.
Today nitrile is commonly used in the transportation and automotive industries because of its outstanding oil, fluid, and wear-resistant properties. Nitrile is particularly good at resisting petroleum-based oils, making it a prime candidate for seals in cars.
This material can stand up to industrial applications and it’s more economical than silicone. Keep in mind, however, that the more specialized your project, the more material can get more expensive as the requirements increase. For example, if you need a hydrogenated nitrile that can sustain a wider range of temperatures and has better wear capabilities, your cost may increase upwards into the range of some silicones.
Fluoroelastomer: An Evolved Product for High-Performance Builds
Fluoroelastomer serves many of the same needs as nitrile, but it’s an evolved product and can sustain much higher temperatures. Where nitrile tops out at 250 degrees Fahrenheit, fluoroelastomer can withstand up to 500 degrees Fahrenheit. It can also survive in cold climates with brittle points down to -40 degrees Fahrenheit.
This oil- and fuel-resistant material is ideal for high-performance engines in automobiles and a great choice for aerospace product designs. One thing engineers love about fluoroelastomer is that it can be tailored to suit application requirements. We often recommend specialty variants of fluoroelastomer for aerospace customers who need additional low-temperature properties.
Whatever you’re creating, there’s an elastomer that will fit your specifications. With 35+ years of experience working with elastomers, our team at Micro-Tronics can help your team identify the best custom molded rubber for your application.
To get started, download our guide to see which material will best fit your needs. When you’re ready to request a quote, our experts will be here, ready to help you bring your elastomer product to life.
4 Things to Look For in a Rubber Product Manufacturer
Rubber is a popular material for a variety of products and applications. By processing and vulcanizing various natural materials, like latex and isoprene, in different ways, rubber product manufacturers can produce different types of rubber that are suitable for everything from car tires, boots, gloves, and waterproof products to erasers, medical devices, balls, and more. There is also a growing number of synthetic rubbers being made to meet specific applications, and innovative rubber manufacturers are experimenting with new combinations and processes that will better serve these applications.
There are many companies that work with rubber, but they’re not all equally suited to create the products you need. Here, we share the top factors to consider when choosing a rubber product manufacturer.
Reputation & Experience
Your rubber manufacturer should have a reputation for high-quality products, friendly and reliable service, financial success year over year, strong leadership, social and environmental responsibility, and more. You should be able to find evidence of this in the supplier’s long-time customers, glowing reviews, community involvement, and online image.
Manufacturers earn that high level of reputation through experience. It’s a good sign when a company has been around for years, particularly if it persisted and even grew during challenging times. Look for ongoing improvements, like a history of buying new equipment, expanding operations, opening larger facilities, hiring more employees (while retaining their long-time experts), or learning new skills and processes.
Long-Term Value
You should choose a supplier based on value, not price. While it may seem tempting to save money, you must consider the long-term ramifications of what may be a sub-par product, even if it is less expensive. Value includes elements that price doesn’t: the rubber product manufacturer’s knowledge and experience, attentive customer service, and more. High-value solutions may cost more, but they also last longer and perform better, which ultimately impacts your reputation and your relationship with your customers.
Your products should be built to last, and you want to work with a rubber manufacturer that uses high-quality materials. Prototyping services and rigorous testing procedures ensure your products will withstand the real-life conditions they will face. This is even more important for specialized items that will be put to work in extreme environments.
Specific Requirements
With so many types of rubber and associated applications out there, you should ensure your chosen rubber manufacturer has the capabilities and experience to manage your specific requirements. If you need to meet the strict regulations and safety standards in the aviation industry, for example, you want to work with a company that is familiar with that industry and has a successful track record of producing rubber products for those applications. In the best-case scenario, you’ll develop a long-term working partnership with your rubber manufacturer, creating a mutually beneficial arrangement that will help both businesses grow.
It’s also essential for your rubber product manufacturer to hold professional industry certifications demonstrating a commitment to quality, service, and meeting customer expectations. This includes ISO 9001:2015, ITAR, NADCAP, and more.
Scope of In-House Manufacturing Capabilities
The scope of your project will help determine how many complimentary services, capabilities, and in-stock raw materials you’ll need your chosen manufacturer to provide. Checking a supplier’s website is a good starting point; if the company seems to only specialize in one area and doesn’t offer the secondary services you’re looking for, partnering with that company might add time and cost to your project.
For example, let’s say you’re looking to create bonded seals. Partnering with a manufacturer that has all the key elements to create this bonded rubber product in-house – including rubber and metal raw materials, mold and tooling staff, metal fabrication machinery, assembly, special marking, and packaging – can shorten your production timelines and reduce your project costs.
The alternative to using a one-and-done manufacturer may be more costly and complicated. For the bonded seals example, this means having to find independent suppliers for each component:
Rubber parts: Building molds and dies and producing rubber components with a rubber manufacturer
Metal parts: Partnering with a machine shop to supply just the metal components that will eventually need to be bonded to the rubber parts
Bonding: Finding a provider who has the machinery to bond the rubber and metal components together
Assembly shop: This can include kitting, laser marking, bag and tag, and final packaging to prep products for sale
At MTI, we have a broad scope of in-house services for our clients, including metal and rubber manufacturing, bonding, and final assembly. By having all areas of support on-site, you can cut weeks to months off of startup lead time.
Learn More About Our Rubber Products & Services
For more than 50 years, Micro-Tronics has been solving complex rubber manufacturing challenges for clients around the globe. We rise to the occasion with innovative solutions serving a number of industries, including aerospace and transportation, medical devices, industrial, electronics, and more.
As a family-owned rubber product manufacturer with more than 150 experts working in Tempe, Arizona, we’ve built our reputation on high-quality products, the ability to grow and adapt to changing consumer demands, and a positive company culture that promotes employee longevity and professional development. Our scope of in-house manufacturing services includes in-house tooling for mold and die creation, rubber molding, kitting, assembly, and more.
Rubber diaphragms are flexible barriers designed to separate one chamber from another in fluid or pneumatic systems (e.g., valves, pumps, meters, regulators, and other control devices). They are available in numerous variations to suit different applications; for example, they can be static or dynamic, thin or thick, rubber or plastic, and molded or machined? However, regardless of the intended application, they must be carefully designed and constructed to ensure fluid or air transfer occurs as expected.
Below, we highlight some of the key considerations to keep in mind when choosing a rubber diaphragm for a fluid or pneumatic system. Additionally, we indicate some of the qualities to look for in an ideal manufacturing partner to ensure the rubber diaphragms you receive fully meet your needs.
What to Consider When Choosing a Rubber Diaphragm
There are many factors to consider when selecting a rubber diaphragm to ensure it operates and performs as intended within the application. Some of the key considerations include:
Process media. The material of the rubber diaphragm should be chemically compatible with the process media, meaning it should be able to resist corrosive damage if the process media is acidic or caustic. Additionally, if the process media is laden with particulates and solids, it should be able to withstand wear and friction.
Operating conditions. Whether the diaphragm is exposed to high temperatures or low temperatures and high pressures or low pressures, it should be able to maintain the desired performance levels throughout its flex life.
Flex life. Flex life is the amount of time a diaphragm can be used in a certain application before it requires replacement. Ideally, you should choose a diaphragm that offers the greatest mean time between replacements (MTBR).
Sanitary standards. Some industries have strict sanitary standards, such as the food and beverage industry or the pharmaceutical industry. If a diaphragm is intended to be used in these industries, it must comply with the relevant sanitary standards.
The total cost of a rubber diaphragm includes many factors, including initial purchase price, rated flex life, replacement costs, and profit loss due to downtime. The rubber diaphragm you choose should suit your application requirements and your budgetary restrictions.
What to Look for in a Rubber Diaphragm Manufacturer
Given the many considerations to keep in mind when choosing a rubber diaphragm, you may find it difficult or daunting to find the right component for your needs. However, an experienced and knowledgeable rubber diaphragm manufacturer can help you navigate all of these factors and identify which product is best suited for your application. Additionally, if an off-the-shelf product is not appropriate, they may be able to develop a custom solution that is tailored to your exact specifications and standards.
Some of the qualities to look for in a rubber diaphragm manufacturer include:
They should have the knowledge to help you choose the right product design, material, etc.
They should have experience providing products for applications similar to your own.
They should have the resources available to produce standard or custom diaphragms that meet your needs, whether that means meeting your design, material, or production quantity requirements.
Why Partner With Micro-Tronics for Your Rubber Diaphragm Needs?
Rubber diaphragms are a key component of many fluid systems. As such, ensuring you have ones that meet your specifications and standards is vital.
Looking for a reliable supplier of quality rubber diaphragms? Micro-Tronics, Inc. has got you covered.
At MTI, we are a leading manufacturer of precision rubber components. One of our core product offerings is cloth-reinforced diaphragms. We can tailor them to suit your application’s requirements and your industry’s regulations. Our in-house testing capabilities and partnerships with independent certified laboratories allow us to provide product validation.
To learn more about our products and services, contact us today. To discuss your rubber diaphragm specifications with one of our experts, request a quote.
