How Does Composite Moulding of FKM and FFKM Save Costs?

FKM and FFKM are incredibly useful elastomers that are commonly used across a wide range of different industries and applications. Composite moulding of these two materials can present advantages in comparison to each material’s own respective benefits that could suit your business’ specific requirements. To find out more about how composite moulding of FKM and FFKM can save costs in a practical manner, continue reading this blog from TRP Polymer Solutions.

What is FKM

FKM, or fluoroelastomers are a type of durable elastomer used for the manufacture of various components found in a diverse range of industries. FKM is commonly used in  oil seals, automotive rubber seals and marine rubber products in addition to many other items. Their permeation resistance, temperature range and chemical resistance make them an excellent choice for many applications.

What is FFKM?

FFKM, or perfluoroelastomers, are a group of elastomers that are utilised for their significant durability and reliability, especially when used in tough environments. With resistance to extreme temperatures, both high and low, chemical resistance, weatherability and more, they have become commonplace in setting the leading standard for resistant polymers.

They are used to manufacture similar components to FKM and are found in industries where these qualities are of utmost importance, including in chemical processing and aerospace applications. In essence, FFKM and FKM share similar properties, though FFKM presents a higher level of chemical and temperature resistance but at a higher cost of manufacturing.

Using composite moulding of FKM and FFKM

The benefits of both materials can be combined by creating products using both. A main advantage of composite moulding of FKM and FFKM is its cost-effectiveness. So, if costing is critical within your project, this method of production can be a valuable trade-off between the two qualities of these rubbers.

Using FFKM as a veneer

Composites are often made by using FFKM as a veneer on a product made from FKM. This provides the high degree of chemical protection that FFKM is favoured for but reduces the cost of the product due to not being wholly made from FFKM, as FKM is a cheaper material to manufacture. Essentially, these composites combine the budget-friendliness of FKM with the performance profile of FFKM. 

As the chemical structures of FKM and FFKM are so similar, it’s possible to create a chemical bond between the layers of each that prevents the need for joining them through adhesives after moulding. In both static and dynamic applications, the use of adhesives to join elastomers can often present weak points where chemical resistance is reduced and tear initiation points can occur. As a result, composite moulding of FKM and FFKM provides the durability you would expect from both materials respectively.

Additional methods of composite moulding

Using a composite is a highly practical idea for applications where only a particular section of a seal is in contact with aggressive media. In these instances, it can be beneficial to have just one portion of the product moulded with FFKM, whilst the rest is FKM. This can reduce the higher cost that typically comes with FFKM components whilst still providing the required chemical resistance.

For dynamic applications that require specific performance profiles, it’s often more cost-effective to develop an FKM that meets these dynamic criteria and then bond an FFKM to provide the chemical resistance.

Certain FKMs can provide special properties, such as ultra-low temperature resistance. Utilising an FKM with these properties to energise a component, and adding an FFKM to provide chemical resistance can provide a unique solution.

To illustrate how we can provide products taking advantage of the benefits of FFKM and FKM, the above is a photo of a cross-section of a diaphragm that uses an FFKM veneer (seen in black) on top of an ultra-low temperature FKM. This was done to allow the diaphragm to function at low temperatures whilst providing high chemical resistance.

Composite moulding of FKM and FFKM at TRP Polymer Solutions

If you think you could benefit from the combination of high performance and cost-effectiveness that composite moulding of these two elastomers can provide, we can provide the solution you’re looking for. We’ve been producing high-quality custom rubber components at TRP Polymer Solutions for over 20 years, so you can trust us to provide you with dependable solutions that meet your budget requirements

Our custom rubber solutions, including our FFKM ‘O’-rings and seals, custom moulded rubber seals and custom rubber diaphragms are able to be produced using elastomer materials that have the necessary attributes required for optimal and dependable performance within your application. To find out more about the types of FKM and FFKM that our custom components can be made from, you can find in-depth information on each in our material datasheets.

For more information on our FFKM and FKM composite products and how TRP Polymer Solutions can assist your business, please contact us. Our technical team can provide expert advice and solutions tailored to your needs.