For the same purpose, we employ cellular manufacturing techniques.  That means we’ve engineered a fully integrated production line that takes our products from gel material to end-product packaging.  This leading-edge methodology promotes efficiency, consistency and effective quality assurance.

Here are the primary processes GEL SMART uses for basic production and value-added finishing:

• Tooling
• Molding
  - Injection
  - Open-Pour
  - Compression
• Extrusion
• Coating and Die-Cutting
  
• Dipping
  

For complete turnkey solutions, we also offer customized finishing processes, including: laminating, die cutting, logo application and packaging for a complete turnkey product.

Tooling
GEL SMART’s in-house machine and tool shop is equipped with two high-speed machining centers dedicated to production tooling and creating your sample.  Our ability to machine, polish, assemble and maintain your production tooling at the point of production eliminates the uncertainties and costs of dealing with outside contractors.  In addition to cutting your tooling costs, we can cut weeks off initial production schedules and avoid costly delays later on for lower significant overall savings.

 
Molding

Injection Molding

Injection Molding – used for producing small to medium-sized components (up to 24 x 24 inches in sheeting form) from:

• S-GELS originating as liquid vulcanized silicone
• M-GELS at very low force
• T-GELS in pelletized form

Open Pour/ Open Casting – This is the method typically used for molding our M-GELS as well as RTV (room temperature vulcanized) formulations of S-GELS. 

Open Pour

Our specialized hot melt process pumps hot gel through a hose and heated nozzle on a timer for an equal-weight shot every time.  Engineered for flexibility and integral quality control, the system controls and guarantees pour accuracy.  It eliminates the inconsistent and poor quality that results from relying on operators to pour gels into molds in typical equipment configurations.

Compression
Compression moldeding is used for M-GELS but is not suitable for our S-GELS.  Gel under pressure is forced into a two-part cavity mold, compressed and then cooled.  Compression is the preferred process for applying gel to a fabric textile or cloth.

GEL SMART’s special expertise in molding includes capabilities for:

• Gel-on-fabric application.  Gel shapes are cast onto fabric, then heat-melded, ironed to the right shape and fused with the fabric.  Uses include orthopedic sleeves, sock and tubing.
  
• Dual-durometer molding combining gels with different hardness and feel in one product for optimal performance and pricing.  Suitable for a variety of foot cushioning products, this system is often used for insoles and heel cups.
  
• Two-color molding 
  
• Combining elastomers into molded foam products
  
• Laminating   
  

Extrusion
Extrusion is suitable for converting T-GELS in the 3-4 durometer range or harder.  This process is useful for making tubing, gel sheeting and continuous-shape parts. 


Coating and Die-Cutting
GEL SMART offers exceptional coating capabilities, including thickness ranges from 1 mm minimum to maximum 100 mm.  We have the special expertise needed to ensure good results when applying gels to fabrics and cutting them down to specified shapes. 

A deceptively simple process, coating gel products requires skill and precision in matching the right fabric with the right gel, using the best-suited process and construction.  Molds and die cuts must also be designed to avoid common problems such as frayed or weakened edges.  Our “cellular” production line incorporates precise design techniques and safeguards to guarantee good fabric/gel matches and problem-free construction.

M-GELS are often used to coat non-woven seamless fabric typically used for disposable convenience products.  The coated fabric is then cut into shapes such as tubing for digital caps — or cushioning and ergonomic positioning pads, such as mattress overlays or wheelchair cushions.


Dipping
GEL SMART’s technology allows us to hold tolerances precisely during dipping to produce coatings ranging from ultra thin 1 mm to a maximum of 5 mm in thickness — in lengths from 1 to 15 mm.  The real secret lies in our gel formulations.  No one can match us.