NBR foam float
FEATURES
NBR Foam Float Product Introduction
1.1 What is an NBR Foam Float?
An NBR foam float is a closed-cell foam device composed of nitrile butadiene rubber (NBR) and phenolic resin, designed to measure liquid levels based on the up-and-down movements of the liquid surface. The float features a self-contained, independently sealed cellular structure where each cell is completely closed off from adjacent cells. This unique structure allows the float to completely block liquid penetration, ensuring reliable buoyancy even if the outer surface becomes damaged.
Key Applications:
Fuel tank level gauges (automobiles, motorcycles, trucks)
Carburetors (motorcycles, agricultural machinery engines)
Engine oil level gauges
Transformer oil level indicators
LPG level gauges and valves
Industrial liquid level sensors
Pneumatic auxiliary components (auto drain)
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Mold Description
Product Materials:
NBR FOAM
Mold Material:
S136ESR
Number of Cavities:
32
Glue Feeding Method:
COLD runner
Cooling Method:
Water cooling
Molding Cycle
42.5s
- The mold manufacturing process and product material selection
Material Composition and Properties
NBR is a synthetic rubber copolymer of butadiene and acrylonitrile. For float applications, NBR is compounded with phenolic resin (a thermosetting resin), curing agents (sulfur-based crosslinking agents), blowing agents, and other chemical additives.
Standard Material Formulation:
Base polymer: NBR (nitrile butadiene rubber) – provides oil/fuel resistance
Reinforcing resin: Phenolic resin – enhances heat resistance and structural rigidity
Crosslinking agent: Sulfur (≤14 wt% of compound) – enables vulcanization
Blowing agent: Generates closed-cell foam structure
Additives: Plasticizers, accelerators, stabilizers
Key Material Properties:
Property Value/Rating Test Standard
Temperature Range -50°C to 180°C (depending on grade) JISK6301
Oil/Fuel Resistance Weight change <0.5% in gasoline, benzene, alcohol, toluene In-house soak test
Compression Set ≤25% (ASTM D1056) ASTM D1056
Density Range 40–88 kg/m³ (2.5–5.5 PCF) ASTM D1056
Pressure Resistance Withstands 2–3MPa with minimal water absorption In-house test
Low-Temperature Performance Stable down to -50°C JISK6301
High-Temperature Performance Up to 180°C under certain conditions In-house test
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Why NBR is the Preferred Material:
Superior fuel/oil resistance – NBR is a representative oil-resistant synthetic rubber with excellent resistance to non-polar media such as gasoline, light oil, and kerosene
Closed-cell foam structure – Each cell is independently sealed, preventing liquid ingress and ensuring permanent buoyancy
Dimensional stability – Very limited variation in dimensions with excellent quality control (Cp, Cpk measurable)
Mechanical strength – The ebonite-like structure provides sufficient strength for post-processing operations such as metal or magnet insert molding
Chemical resistance – Excellent resistance to fuels, oils, alcohols, and various hydrocarbons
Wear resistance and aging resistance – Maintains performance over extended service life
Part II: Manufacturing Process & Production Workflow
2.1 Two-Stage High-Pressure Foaming Process
Ansix employs the industry-proven high-pressure two-stage foaming (double-stage foaming) method, which is widely recognized as the superior manufacturing technique for NBR foam floats.
Stage 1 – Primary Vulcanization:
The NBR compound (FMB – Foam Material Base) is prepared through a roll milling process
The compound is aged to allow proper chemical maturation
Primary vulcanization begins under controlled temperature and pressure conditions
The material partially crosslinks while the blowing agent initiates gas generation
Stage 2 – Secondary Vulcanization & Foaming:
The partially cured material undergoes secondary vulcanization at elevated temperatures
Full foaming occurs as the blowing agent completes gas expansion
The closed-cell structure is permanently set through complete crosslinking
Advantages of Two-Stage Foaming:
Nearly perfect closed pores – The floats maintain buoyancy even with surface damage
High foamability – Minimum specific gravity of approximately 0.15 can be achieved
Superior dimensional stability – Controlled foaming ensures consistent part geometry
Easy post-processing – Cutting, drilling, and bonding operations are straightforward
2.2 Complete Manufacturing Workflow
Step 1: Material Preparation
Raw material inspection (NBR, phenolic resin, curing agents, blowing agents)
Precise weighing and compounding according to proprietary formulation
Roll milling to achieve homogeneous dispersion
Step 2: Aging
The FMB (Foam Material Base) is aged for chemical maturation
Aging time and conditions are precisely controlled for optimal foaming characteristics
Step 3: Molding
The aged material is placed into precision molds
High-pressure molding under controlled temperature and time parameters
Primary vulcanization and foaming initiation
Step 4: Secondary Vulcanization
Post-curing at elevated temperatures
Complete foaming and cell structure stabilization
Full crosslinking for optimal mechanical properties
Step 5: Demolding & Trimming
Controlled cooling and demolding
Flash removal and edge trimming
Surface inspection
Step 6: Post-Processing (if required)
Insert molding (metal, magnet)
Cutting, drilling, bonding
Surface treatment or coating
Step 7: Quality Inspection
Dimensional verification
Density measurement
Buoyancy testing
Soak testing in fuel/oil baths
Pressure resistance testing
Step 8: Packaging & Delivery
Custom packaging solutions
Traceability labeling
Logistics coordination
Part III: Ansix's Hard Power Infrastructure
3.1 Mold Manufacturing Equipment
Five-Axis High-Speed Machining Centers
Capable of machining complex curved surfaces with 0.002mm precision
Ensures smooth, burr-free parting lines on finished products
Enables complex geometry manufacturing for custom float designs
Slow-Wire EDM (Electrical Discharge Machining)
Capable of producing 0.03mm fine micropores and narrow slots
Prevents thin-wall deformation during machining
Essential for precision features in float molds
Precision Grinding Equipment
Surface grinding for critical mating surfaces
Coordinate grinding for precise cavity dimensions
In-House Electrode Machining Center
Self-built electrode processing capability
Rapid turnaround for mold repairs and modifications
Eliminates dependency on external suppliers for emergency repairs
3.2 Injection Molding Machine Fleet
Machine Range: 30 tons to 4,000 tons clamping force
Covers a comprehensive range of product sizes
Flexible capacity allocation for different production volumes
All-Servo Electric Drive
Stable repeatability precision of ±0.1%
Every shot is consistent across entire production batches
Energy-efficient operation reduces manufacturing costs
Key Capabilities:
Multi-cavity molding for high-volume production
Insert molding (metal, magnet)
Hot runner systems for reduced material waste
Dual-color/multi-material molding capability
3.3 Inspection & Quality Equipment
Coordinate Measuring Machines (CMM)
Full dimensional inspection of molds and parts
Comprehensive dimension reports for every mold before delivery
Critical dimension CPK ≥ 1.33 guaranteed
Optical Inspection Systems
High-resolution vision inspection for surface defects
Automated dimensional verification
Real-time quality monitoring
Material Testing Equipment
Hardness testing (Shore A/D)
Density measurement systems
Compression set testing apparatus
Soak test facilities for fuel/oil resistance verification
Part IV: Mold Design & Manufacturing Core Competencies
4.1 Mold Design Highlights
Mold Flow Analysis (MFA) – DFM Report
Ansix provides comprehensive Design for Manufacturing (DFM) reports before mold manufacturing commences, including:
Draft angle recommendations
Wall thickness optimization
Gate location and configuration
Ejector pin mark position allowances
Weld line and air trap prediction through mold flow analysis
Shrinkage compensation calculations
Mold Types Offered:
Hot runner systems – Reduced material waste, faster cycle times
Stack molds – Double production efficiency
Two-color/multi-material molds – Complex integrated components
High-gloss molds – Surface roughness Ra < 0.05μm for transparent parts
Insert molds – Metal or magnet insert integration
Gate & Runner System Design:
Optimized gate location and quantity through mold flow analysis
Balanced filling to prevent weld lines and air traps
Minimized material waste through runner optimization
Cooling System Design:
Conformal cooling channels for uniform temperature distribution
Mold temperature controller (MTC) with zone control
Core and cavity temperature difference controlled within 2°C
Minimizes warpage and dimensional variation
Ejection System Design:
Optimized ejector pin placement
Minimal visible ejector marks on cosmetic surfaces
Balanced ejection forces to prevent part deformation
4.2 Mold Materials Selection
Component Material Options Key Characteristics
Mold Base P20 Good machinability, structural stability
Mold Core/Cavity S136, 2344, 2343, 8407 High wear resistance, corrosion resistance
SKD11, SKD61, DC53 Excellent toughness, wear resistance
M340, 4Cr13, 9Cr18 High hardness, corrosion resistance
NAK80 Pre-hardened, excellent polishability
H13 High-temperature performance, thermal fatigue resistance
Material Selection Criteria:
For glass-fiber reinforced materials: ≥500,000 shot life guaranteed
For standard plastics: ≥1,000,000 shot life guaranteed
Full material certificates and heat treatment curves provided
4.3 Mold Manufacturing Process
Step 1: Rough Machining
Rough milling of mold base and cavity blocks
Stress-relief heat treatment
Step 2: Precision Machining
Five-axis high-speed machining for complex geometries
Precision grinding for critical surfaces
Step 3: EDM Processing
Slow-wire EDM for fine features
Sinker EDM for complex cavities
Step 4: Fitting & Assembly
Precision fitting of core and cavity
Guide pin and bushing installation
Ejection system assembly
Step 5: Surface Finishing
Polishing to specified surface roughness
Texture application if required
Coating application (if applicable)
Step 6: Mold Trial & Validation
T0 to T3 trial shots with improvement reports
Quick-change insert capability for design verification
Full dimension report before delivery
Step 7: Mold Delivery
Complete documentation package
Spare parts (ejector pins, core inserts) included
Maintenance schedule provided
4.4 Precision & Tolerance Capabilities
Feature Type Achievable Tolerance
General structural parts ±0.05mm
Precision gears/medical components ±0.005mm
Parting line flash control ≤0.03mm
Surface roughness (cosmetic) Ra ≤ 0.2μm
Surface roughness (high-gloss) Ra < 0.05μm
Printing registration accuracy ±0.1mm
4.5 Mold Delivery Standards
Mold Complexity Standard Lead Time Expedited Lead Time
Simple molds 10 days 7 days
Medium complexity 25–45 days 20 days
Complex molds 45–60 days 35 days
Note: Expedited delivery does not compromise quality verification – all validation steps are maintained.
Part V: Injection Molding Process Control
5.1 Process Standardization
MES System Integration
All machines connected to Manufacturing Execution System (MES)
Molding parameters (temperature, pressure, speed, time) locked in MES
Parameter changes require engineer authorization only
First-article and last-article comparison for every batch
Closed-Loop Control
Ultrasonic wall thickness sensors for real-time monitoring
Automatic compensation of holding pressure based on wall thickness feedback
In-mold temperature and pressure sensors for closed-loop process control
5.2 Dimensional Stability Control
Temperature Management
Mold temperature controller (MTC) with zone control
Core and cavity temperature difference within 2°C
Minimizes warpage and distortion
Stability Data:
For similar bracket products: key hole spacing variation ≤ 0.02mm across three consecutive production batches within one week
Repeatability precision of ±0.1% across all production shots
5.3 Cosmetic Quality Standards
Appearance Requirement Achievable Standard
Transparent parts No bubbles, no flow marks
Plated parts No gas marks
High-gloss parts Surface roughness Ra ≤ 0.2μm
Painted/printed parts Pre-compensated for deformation; registration accuracy ±0.1mm
5.4 Special Material Processing Capabilities
Ansix has extensive experience processing a wide range of engineering plastics:
PC/ABS
PC (Polycarbonate)
PPS + 40% GF
PEEK
PTFE/PFA
PA6 + GF30
PBT
PEI/PPS/LCP
Liquid Silicone Rubber (LSR)
Special Requirements:
Flame retardancy: UL94 V-0 rated for coil housings and similar applications
Weather resistance: UV testing up to 3,000 hours without discoloration
Part VI: Quality Assurance System
6.1 Incoming Material Quality Control
Raw material supplier qualification and audit
Material certificate verification
Incoming inspection (hardness, density, rheological properties)
Traceability from batch to finished product
6.2 In-Process Quality Control
Parameter Monitoring
Real-time monitoring of all molding parameters
Automated alerts for parameter deviations
Statistical Process Control (SPC) implementation
Inspection Frequency
First-article inspection for every production run
Patrol inspection at defined intervals
Last-article inspection before batch completion
6.3 Finished Product Quality Control
Dimensional Inspection
CMM measurement for critical dimensions
Optical inspection for surface defects
CPK calculation for key characteristics (≥1.33 target)
Functional Testing
Buoyancy test – Verified in fresh water under controlled conditions
Soak test – Weight and dimension change measurement after fuel/oil immersion
Pressure resistance test – 0.5–3MPa for 10–30 minutes
Density measurement – Deviation within ±1.5% of nominal value
Compression set test – ≤25% per ASTM D1056
Water absorption test – ≤3% weight gain after 24-hour immersion
Appearance Inspection
Surface defect inspection
Color verification
Flash measurement (≤0.03mm controlled)
6.4 Certification & Standards Compliance
ISO 9001 quality management system
RoHS compliance
SVHC compliance
EN71 compliance (where applicable)
ISO/TS16949 (automotive grade where applicable)
UL certification for flotation applications (UL-1191)
6.5 2000-Shot Aging Test
Before mold delivery, Ansix conducts a 2,000-shot aging test and provides a comprehensive wear report. This ensures:
Mold performance validation before production
Identification of potential wear issues
Confidence in mold life guarantees
Part VII: Cost Optimization & Efficiency
7.1 Material Cost Optimization
Precise Material Formulation
Proprietary compounding expertise minimizes material waste
Optimized material selection balances performance and cost
Bulk purchasing power for raw materials
Hot Runner Systems
Reduces material waste from cold runners
Faster cycle times improve throughput
Lower per-part material cost
Regrind & Recycle Capability
In-house regrind capability for production scrap
Closed-loop recycling reduces material cost
7.2 Process Efficiency Optimization
Cycle Time Reduction
Optimized cooling system design minimizes cooling time
High-speed injection molding capability
Multi-cavity molds for high-volume efficiency
Automation Integration
Robotic part removal and handling
Automated inspection systems
Automated packaging systems
Energy Efficiency
All-servo electric drive machines
Energy consumption reduced by 40-70% vs. hydraulic machines
Lower operational costs passed to customers
7.3 Production Efficiency Metrics
Efficiency Metric Ansix Capability
Machine utilization ≥85%
First-pass yield ≥98%
Overall Equipment Effectiveness (OEE) ≥80%
Scrap rate ≤2%
7.4 Tooling Cost Optimization
Modular Mold Design
Interchangeable inserts for different product variants
Reduces tooling investment for product families
Faster changeover between variants
Standardized Components
Use of standard mold bases and components
Reduces manufacturing cost and lead time
Easier maintenance and repair
Part VIII: Delivery & Logistics
8.1 Production Planning
Demand forecasting – Proactive capacity planning based on customer forecasts
Flexible scheduling – Accommodates rush orders and schedule changes
Safety stock – Strategic inventory for critical components
8.2 Delivery Lead Times
Order Type Lead Time
Prototype samples 7–15 days
Pilot production (100–500 shots) 10–20 days
Mass production (first batch) 15–30 days
Repeat orders 7–15 days
8.3 Packaging Solutions
Custom packaging design per customer requirements
Protective packaging to prevent damage during transit
Traceability labeling for batch tracking
Blister packaging, bulk packaging, or custom solutions
8.4 Logistics Coordination
Multiple shipping options (air, sea, land)
International logistics expertise
Customs clearance support
Real-time shipment tracking
Part IX: Full-Service Value Proposition
9.1 Early Engagement – DFM (Design for Manufacturing)
Before signing a contract, Ansix provides a comprehensive mold feasibility analysis report covering:
Draft angle recommendations
Wall thickness optimization
Gate location and configuration
Ejector pin mark position allowances
Weld line and air trap identification
Shrinkage compensation recommendations
Material selection guidance
Customer Value: Problems are identified and solved before mold manufacturing begins, preventing costly redesigns and delays.
9.2 Prototyping & Sample Development
T0 to T3 Trial Shots
T0: First trial – identifies initial issues
T1: First improvement – addresses critical issues
T2: Second improvement – fine-tunes process
T3: Final verification – ready for production release
Improvement Reports
Comprehensive reports for each trial round
Quick-change insert capability for design verification
No need to rebuild entire mold for design changes
9.3 Pilot Production Verification
Before full-scale mass production, Ansix provides 100–500 shot pilot production:
Statistical yield analysis
CPK calculation for critical dimensions
Process capability verification
Production readiness confirmation
Customer Value: Production stability is confirmed before committing to mass production, eliminating costly production surprises.
9.4 Maintenance & Spare Parts
Spare Parts Package
Ejector pins, core inserts, and other wear parts included with mold delivery
Ready inventory for immediate replacement
Preventive Maintenance
Maintenance schedule provided with every mold
Maintenance at every 200,000 shots recommended
Life-long repair service at cost price
Rapid Repair Capability
In-house electrode machining center and EDM workshop
Mold repairs completed without leaving the factory
Standard repairs (welding/insert replacement) completed within 24 hours
Part X: Differentiated Advantages – Addressing Common Industry Pain Points
Common Customer Complaint Ansix's Solution & Commitment
Frequent mold repairs disrupting production 2,000-shot aging test before delivery with wear report; 3-year mold structure warranty (excluding normal wear parts)
Excessive flash increasing post-processing cost Parting line machining to 0.005mm fit precision; self-locking clamp force compensation; flash controlled to ≤0.03mm per batch – eliminates manual deburring
Inconsistent dimensions across batches Ultrasonic wall thickness sensors for real-time monitoring; automatic holding pressure compensation; in-mold temperature/pressure sensors for closed-loop control
Long mold repair lead times In-house electrode machining center and EDM workshop; repairs completed in-house; standard repairs (welding/insert replacement) within 24 hours
High material waste Hot runner systems reduce waste; optimized runner design; regrind and recycle capability
Uncertain mold life Clear material-specific life guarantees: ≥500,000 shots for glass-fiber reinforced materials; ≥1,000,000 shots for standard plastics
Part XI: Customer Value Summary – The Ansix Difference
What Ansix Solves for Customers
Customer Challenge Ansix Solution Value Delivered
Design uncertainty DFM report before mold manufacturing Problems solved before investment – no costly surprises
Quality inconsistency MES-locked parameters + closed-loop control Every part consistent – no batch-to-batch variation
High scrap rates Process optimization + real-time monitoring Scrap rate ≤2% – direct cost savings
Long lead times In-house capabilities + efficient processes 10–60 day delivery – faster time-to-market
High tooling costs Modular design + standardized components Lower initial investment – better ROI
Maintenance headaches Spare parts included + 24-hour repair Minimal downtime – uninterrupted production
Logistics complexity End-to-end supply chain management One less thing to worry about – focus on core business
Cost Savings Summary
Cost Category Savings Achieved
Material cost Optimized formulations + hot runner systems + regrind capability
Labor cost Automation integration + efficient processes
Tooling cost Modular design + standardized components
Quality cost First-pass yield ≥98% + CPK ≥1.33
Logistics cost Optimized packaging + efficient supply chain
Risk Reduction Summary
Risk Category Mitigation
Design risk DFM report identifies issues before manufacturing
Quality risk MES-controlled processes + comprehensive testing
Supply risk Strategic inventory + flexible capacity
Performance risk 2,000-shot validation + material certifications
Obsolescence risk Modular design allows easy updates
Conclusion: More Than Just a Mold – A Printing Press for Your Business
At Ansix, we believe that a mold is not just a piece of steel – it is a printing press that generates value for your business. Every mold we design is engineered with comprehensive consideration of:
Rigidity – For consistent performance over millions of cycles
Exhaust paths – To eliminate gas traps and burning
Temperature balance – For dimensional stability and reduced cycle time
Our goal is to deliver molds that arrive at your production line ready to run – no debugging, minimal flash, and long service life.
We invite you to experience the Ansix difference. Request a full DFM report walkthrough on an existing product, and see firsthand how we identify and solve potential issues – weld lines, gas traps, shrinkage – before they become problems.
Ansix Tech – 28+ Years of Manufacturing Excellence in NBR Foam Float Solutions
Ansix Tech Co Ltd
If you have any plans related to NBR foam float , you can contact us at any time. We will turn your ideas into reality, let you realize your dreams, and obtain large orders from the market. Our contact information is info@ansixtech.com. Or contact our CTO, mail: stephen@ansixtech.com
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