SRP Delivers Solutions for Success.
It comes down to what you need. From specs and consultation, to design, engineering, and delivery. SRP delivers cost-effective solutions—on time—to your specifications. We have manufactured custom products for a variety of industries using the latest and most sought after non-metallic materials on the market. Check out some of the many solutions we’ve engineered for clients.
Solving An Electrical Arcing Issue Using Flexible Electrical Insulation Material
A customer of ours that is an OEM providing controls in the commercial building industry had an application issue concerning a circuit board.
They were experiencing unanticipated arcing on the circuit board that was resulting in failures in the controls. Electrical arcing is a luminous discharge of current that is formed when a strong current jumps a gap in a circuit or between two electrodes.
The major concern with the arcing was not only the fact that it was causing the controls to fail, however, the arcing could also cause electrocution to the user, or potentially start a re.
With the knowledge that we were dealing with a circuit board application, we understood that electrcity wasn’t the only thing to pay close attention to, but also the heat inside the product. We also knew there was minimal space to work with within the control box.
Our solution to combat all these issues was to use Formex™ flexible polypropylene. Formex™ is a flame retardant material that provides superior electrical insulation and barrier protection in various industrial and consumer electronic equipment.
Using the Formex™ flexible polypropylene, SRP was able to create a spacer that provided electrical insulation to protect the circuit board by preventing the arc gap from arcing to the ground plane.
The exibility and lightweight features of this material made it extremely easy to incorporate into the building of the control box.
Equipment Used: Laser Cutting Materials Used: Formex™ Flexible Polypropylene
High Temperature Gaskets For a High Temperature Application in the Fire and Life Safety Industr
One of our customers who manufacturers fire and life safety devices was in need of a high-performance gasket that offered not only protection against higher temperatures, but also a material that can withstand the life of the smoke detector.
The Fire and Life Safety industry is a very competitive market for manufacturers. When dealing with the safety of ourselves and others, people are more than likely going to seek out the most dependable products from the most dependable brands. It was extremely important to us that we come up with the best solution possible for our customer.
We recommended going with Rogers BISCO Silicone HT-800 foam. This material has a recommended constant use temperature of 392 degrees, perfect for high heat applications.
Also, since the nature of this material does not take a compression set, it was the perfect material for this specific application. BISCO® Cellular Silicones are ideal for sealing, cushioning, vibration isolation, and insulation.
The Rogers BISCO® Silicone HT-800 had zero issues during the testing of the application. The compression set resistance allowed for this gasket to withstand the life of the smoke detector.
Being a Preferred Convertor for Rogers, SRP was quickly able to acquire samples, and get prototypes out in a timely fashion.
Equipment Used: Flatbed Punch Press/Steel Rule Die Materials Used: Rogers BISCO® Silicone HT-800
3M™ Thermal Interface Tape Helps to Improve The Life of a LED Lighting Application
An LED lighting manufacturer came to us seeking ways to improve the lifetime performance of LED bulbs within their fixtures.
This company was previously using a thermal grease to help transfer the heat being created from the bulbs away from the enclosure.
The problem with using a thermal grease is that it can get quite messy, and unless you are used to working with thermal grease, it is hard to apply and evenly distribute.
SRP recommended a thermal interface material to dissipate the heat in the fixture. This material is designed to provide a heat transfer path between heat generating components and cooling devices.
We also suggested a microcellular urethane to prevent environmental contaminants from entering the product. We were con dent this was the perfect solution to prolong the life of the LED bulbs.
Our customer was pleased that their thermal-management product was now higher performing and superior to its predecessor. The elimination of the thermal grease resulted in a much simplified assembly process as well.
These cost saving improvements reduced assembly time immensely, while providing more ef cient distribution of heat throughout the application.
Equipment Used: Laminating | Flat Bed Die Cutting Materials Used: 3M™ Thermal Interface Transfer Tape 8810 | Rogers PORON®
SRP Teams Up with 3M to Manufacture Custom Solutions for a Telecommunications Company
LCI’s, or Liquid Contact Indicator’s, are small indicators that turn from red into another color after contact with water.
A customer in the telecommunications industry came to us looking for a more efficient solution that would enable them to identify water damage inside of their electronic devices using LCI’s.
In case of a defective device, service personnel can check whether the device might have suffered from contact with water. After contact with water, or other liquids, the device is not covered by warranty.
Our partnership with 3M allows us to work as the middle man between supplier and customer. Using their technology and material resources, they were able to produce a proprietary material specially made for our customer.
SRP provided solutions that helped reduce costs by changing the design of the part from a circle to a hexagon shape, which not only helped to increase the yield, but it also reduced the amount of material used in production.
Our customer benefitted from this product immensely. It was a low cost solution to an issue that potentially saved the company millions in warranties from customer’s using their handheld devices.
Equipment Used: Rotary Die Cutting Materials Used: 3M™ 5557 Water Indicator Material Combined + Custom-Made 3M™ Security Tape
Further Improving the Home Improvement Industry by Optimizing the Function of a Protective Gasket.
We were contacted by a customer in the home improvement industry asking for assistance with a challenging product design for a industrial application.
They were using a design that called for a plastic molded gasket protective cover adhered to closed cell sponge on both sides.The plastic offered a wear surface and the sponge, a cushion.
The challenge was to design a part that would offer superior resistance to prolonged usage, while still maintaining it’s performance over an extended period of time.
In an effort to manufacture a product that suited their every need, we offered them a thicker closed cell sponge gasket cover with cut-outs inserted using 3M Bumpon material.
The 3M Bumpon material provided the wear surface required and eliminated the need for the molded plastic piece thus reducing the overall cost.
By working closely with our customer, we were able to design a superior product that was not only better performing, but also more cost effective. This product was tested by their research and development team, and will begin production soon.
Equipment Used: Lamination + Flash Cutting Materials Used: 3M Bumpon Resilient Rollstock + Closed Cell Sponge + Adhesive
Custom Packaging for a Medical Company Using High Density Foam for the Ultimate Protection
A medical company came to us looking for a custom packaging solution to protect their high priced medical devices during transit.
The technological advancement for medical devices and electronics continue to become smaller, thinner, and essentially hand held.
Being that these devices are so valuable, it was important for our customer to feel comfortable when shipping their products to various hospitals.
SRP is not historically known to manufacture custom packaging, but our capabilities allow us to offer value added, high-quality services to t our customer demands.
Utilizing our state-of-the-art waterjet machine, we were able to custom cut slots of various sizes into high-density foam to eliminate breakage during transit. The waterjet is able to cut high density foam up to 3” thick.
The high density foam was very effective at securing the medical devices, not to mention extremely cost effective. Now our customer can safely and conveniently ship their products worldwide.
Equipment Used: Waterjet Cutting Materials Used: High Density Foam
Protecting Automotive Electronic Components From Excessive Wear Using An Electrical Insulator
This customer had a heat sensitive electronic application and was concerned about protecting the internal components from electrostatic discharge and excessive wear.
Without changing the integrity of the final product, they needed to find a material that would not only fix the issues, but is also able to be integrated seamlessly into the application.
Fixing the issue would greatly improve the final product by protecting the internal components of the electronic device.
The solution recommended was to cut a thin layer of Kapton® to apply over the circuit board that would act as an electrical insulator and protection layer for the sensitive components.
Due to the performance of the Kapton® Polyimide Film, coupled with the available thickness, or thinness if you will, there was never a doubt that our manufactured part would make a better end product.
In addition to high performance dielectric insulation properties, Kapton also provided excellent high heat resistance. The unique construction of DuPontTM Kapton® polyimide lm provided the customer with the additional abrasion resistance they were looking for.
Equipment Used: Flat Bed Punch Press | Steel Rule Die-Cutting Materials Used: Kapton® Polyimide Film
Sealing Out the Weather Using Microcellular Urethane Foam
A heating and air conditioning company came to us in search of a more ef cient gasket to seal their units from outside contaminants.
Having a product permanantly outdoors makes the construction of the units more dif cult, especially when dealing with different weather conditions throughout the year.
This goal was to minimize as much risk as possible, without having to change the design of the HVAC units entry doors.
SRP suggested using a microcellular urethane to create a seal to prevent dust, dirt, and water from entering their heating and air conditioning units.
We designed dovetail gaskets to improve material utilization and to also improve the assembly process. This helped lower cost of production for both SRP and our happy customer.
Since the PORON® microcellular urethane has incredible compression set resistance, the sealing gasket will be able to last through the life of the system without any degredation.
Equipment Used: Flash Cutting Materials Used: Rogers PORON® + Pressure Sensitive Adhesive
Eliminating the Need for Mechanical Fasteners in an Automotive Application
A customer in the automotive industry came to us looking for a solution to eliminate the use of mechanical fasteners from their body side molding products.
Mechanical fasteners, when used is abundance, can get heavy. By eliminating these fasteners, companies are able to create lighter parts for vehicles. Mechanical fasteners also make the assembly process more complicated due to the fact that heavier tools are required for installation.
This company was in the market for some type of adhesive that would simply help adhere their product, to the end product.
Nuts and bolts are simply a thing of the past when it come to these types of applications. There are more and more applications that are eliminating the use of these mechanical fasteners everyday.
SRP suggested using VHB™ foam tape to eliminate the need for these fasteners and to prevent corrosion in the product. We also added tabs to the product for ease of assembly, reducing labor overhead. Due to the high production yields, we utilized our rotary die cutter.
Using Foam Tape allowed our customer to assemble the body side molding parts more ef ciently and effectively, and the only tool needed were a workers hands.
The Foam Tape created a lighter product, making the end product more ef cient as well. Not to mention the fact that they no longer needed to drill holes in the vehicles. Less work, less mess, more cost effective.
Equipment Used: Rotary Die Cutting Materials Used: 3M™ VHB™ Foam Tape
Seeking Improvements in the Material Handling Process Through the Use of High Performance Adhesives
A customer in the appliance industry contacted us with a sealing application that required applying an adhesive to a cellular urethane substrate.
The requirements for this adhesive were that they provided a quick initial tack combined with clean removability leaving no residue. It would also be ideal if the adhesive had a thin polyester lm carrier for a stronger hold and ease of use.
Our recommendation for the customer was to offer 3M™ 442F as the ideal adhesive for this particular application. The 442F™ features a thin polyester lm carrier that provides dimensional stability and improved handling with ease of die-cutting and laminating. 442F™ comes standard with 3M™ Adhesive 830.
The 830 is a firm rubber adhesive system that provides a combination of good adhesion, good temperature performance, good solvent resistance and good quick stick to a wide variety of materials as well as clean removability from many surfaces.
After testing and prototyping, the customer agreed that this adhesive was exactly what they were looking for. The performance of the product we provided held up to stability and handling specifications, making their processes more efficient.
Equipment Used: Laminator + Flatbed Punch Press/Steel Rule Die Materials Used: 3M™ 442F Adhesive
Athletic Equipment Manufacturer Seeks to Improve High-Performance Shin Guards
An athletic equipment manufacturing company was developing an ultra high-performance shin guard for their line of soccer equipment.
In order to manufacture the highest performing sports equipment on the market, they started with an aerospace grade 100% Carbon Fiber Composite material for their shin guards.
To complete the product, padding needed to be added for comfortability, and to protect the player from getting hurt or injured.
For the padding, a lightweight, high-performance material was necessary. Our customer selected Rogers PORON® XRD® with Microban® to be adhered to the back of the shin guards.
PORON® materials are ideal for applications where compression set resistance is a key product feature. This feature allowed our part to last throughout the lifetime of the product without any degredation.
SRP’s manufacturing expertise enabled us to produce a custom-shaped pad using PORON® XRD® Extreme Impact Protection urethane foam as a cost-effective solution.
An additional benefit of using this material over conventional foams is it’s infusion with Microban® Antimicrobial Technology to help prevent the growth of bacteria that causes stains and odors.
Equipment Used: Pressure Sensitive Adhesive Laminator | Flash Cutter Materials Used: 2MM THK PORON® XRD® with Microban® technology | 3M™ 9472 Pressure-Sensitive Adhesive
Preventing Hairline Cracks from Forming When Assembling Metal and Plexiglas
One of our customers making aftermarket parts for a motorcycle manufacturer was having difficulties with a windshield application during their assembly process.
When assembling the base of the windshield to metal brackets on the motorcycles, it was creating hairline cracks in the Plexiglas®.
This was obviously a major quality issue, especially when the business model of the company they are selling to maintains the highest quality assurance.
As convertors, we understand that when two objects or parts are being put together, there usually needs to be a separation such as a gasket to aid in the force or tension being created.
SRP recommended separating the steel and Plexiglas® with a microcellular urethane gasket to prevent cracks from being created in the Plexiglas®.
Due to the simplicity of the part, it was an extremely cost effective solution that worked wonders for their product.
The part also provided seamless integration in the assembly process, and the change was virtually unnoticeable due to the thickness of the microcellular urethane.
Since this material does not take a compression set, the product will last for the duration of the final product.
Equipment Used: Rotary Die Cutter | Flash Cutter Materials Used: Rogers PORON®
Helping to Create Cost Effective Solutions to an Existing Product Line in the Appliance Industry
This appliance manufacturing company came to us having already known exactly what they needed from us. It was a lightweight, heat resistant gasket using a common thermal material to create a barrier within the oven door of their products.
This particular application really wasn’t a challenge at all. The work was already done for us. However, we are always looking out in the best interest of our customers. Whenever we can offer a suggestion as to how to make their parts higher performing or more cost effective, we will not hesitate.
Due to our continuing education with 3M, and being up to date on all the latest and greatest solutions on the market, we proposed switching from the insulation paper they had spec’d in to 3M’s new-to-market FRB Series insulation paper.
The 3M™ Flame Barrier FRB Series is flexible insulation for OEM electrical flame barrier applications. The FRB Series products are made primarily of inorganic materials that are intrinsically flame retardant with good dielectric strength.
Not only did it meet every stringent need for their application, but also it came with a 23% lower cost solution for them without sacri cing performance with the potential for a better end product.
Equipment Used: Flatbed Punch Press/Steel Rule Die Materials Used: 3M™ FRB Series NT-15 + 3M™ 467MP Adhesive
Utilizing a Sealing Gasket to Keep Unwanted Evironmental Debris From Damaging a Telecommunications Cabinet
This company was seeking a product for their telecommunications cabinets. These cabinets are built in two separate sections, and then the sections are pieced together at the end of assembly to form one enclosure.
For this, they needed a gasket that would create a seal between the two sections that wouldn’t affect the integrity of the cabinet.
Closed cell sponge rubber with a rubber-based adhesive was the perfect candidate for this application for multiple reasons.
Since the application was non-critical, the material did not require specific properties other than seal- ing out water, rain, and dust. Also, considering the seal will never have to be broken, compression set was a non-factor.
A sponge sealing gasket is all that was needed to protect the cabinets from the outside environment. Simple solution to a pesky issue. The combination of materials, coupled with our manufacturing process, allowed us to offer them the highest performing, lowest cost solution.
Equipment Used: Lamination | Automatic Log Slitting Materials Used: Closed Cell Sponge Rubber + Rubber Based Adhesive
Switching To A More Cost Effective Material, While Maintaining Optimum Performance
This electronics manufacturer was using a silicone interface pad on a heat sink for a small electronics application. The purpose of the interface pad is to provide a preferential heat transfer path between heat generating components to keep the product from overheating, which will eventually damage the product and rendering it useless.
The challenge, however, was not in the functionality of the product, but in the expenditure of the application. Our customer was looking to be more cost effective with their products.
After understanding the temperature specifications of the application, SRP realized that the performance of the silicone adhesive they were currently using was a lot more than what was required.
Our solution was to switch to the 3M™ 5571 Acrylic Thermal Interface Pad to be more cost effective, while continuing to maintain the same performance of the Silicone Pad.
After thorough testing of the new 3M™ 5571 Acrylic Thermal pads, our customer found that this material was more than enough performance to keep their products safe from the heat at a fraction of what they were spending with the silicone interface material.
Equipment Used: Rotary Die-Cutting Materials Used: 3M 5571 Thermally Conductive Acrylic Interface Pad