Silicone Die Customization Services
Selecting the best die for your application
Market-Leading Expertise
United Silicone has the largest die capacity in the market. In addition to standard dies, we are a market-leader in the creation custom die solutions.
Our unique-in-the-market toolless Magnetic Quick-Change Die Mounting System generates significant time and cost savings while our texture application capabilities eliminate voids caused by air entrapment.
Our Dies
Market-Leading Range
Our extensive range of die technologies include:
Silicone Dies
- Flat, Contoured, Crowned, Multi-Level
- Single or Dual Durometer
- Photo-etched and Machine Engraved
- Die Finishing
- Traditional and Magnetic Mounting Formats
Metal Dies
- Steel, Brass, Magnesium
- Flat and Contoured
- Die Finishing
- Traditional and Magnetic Mounting Formats
We Stand Out For
Precision + Efficiency
- Up to 90x faster die changeover speeds (toolless Magnetic Quick-Change Die Mounting)
- Up to 50% improvement in mounting accuracy (Magnetic Quick-Change Die Mounting)
- Application of texture to the die surface to eliminate voids caused by air entrapment.
- CNC machine engraved molds for crowned, contoured and multi-level stamping
- Market-leading die capacity
Silicone Dies
Silicone rubber dies are widely used for the application of hot stamp foil and heat transfers onto flat, contoured or cylindrical-shaped products. At United Silicone, we produce durable, high-precision silicone dies that deliver crisp, clean, impactful decoration to your part.
Our dies provide superior conformity to surface variations, excellent thermal conductivity, high-impact visual performance with wide range of foils.
Additional Benefits
Our silicone dies provide:
| Benefits | Description |
| High Performance Formulations | Our Thermosil® formulation provides heat recovery to the die surface required for high-speed automated and long-dwell time applications. |
| Die Finishing | Our die finishing services include hole drilling, matching dovetail and special trims. We can save you time by providing a completely “ready-to-use” die. |
| Magnetic Die Mounting Systems | Provide for tool-less die changeovers in a matter of seconds while achieving up to 50% improvement in precision alignment performance. |
| Customer Service with Graphic Arts Expertise | Our Customer Service Reps are also graphic arts experts- eliminating “lost in translation” errors when it comes to manipulating and creating your artwork. |
| Superior Silicone-to-Metal Bond | Provides die longevity and repeatability from die-to-die for art location and overall thickness. |
Formats
We manufacture a wide variety of silicone dies – each with its own unique set of benefits and considerations.
| Shapes | |
| Type | Common Uses |
| Flat | Vertical stamping, peripheral and roll-on applications |
| Multi-level | To accommodate small height differences in parts to be decorated |
| Contoured | To precisely match a contoured part that requires decoration |
| Crowned | To eliminate air entrapment or to allow for heat sinks in plastic parts |
| Durometers | |
| Type | Overview |
| Single Durometer | Dies ranging from 40 to 90 durometer to meet a wide variety of needs |
| Dual Durometer | Better conformity to part variation or enhanced capability to stamp combination of fine and bold graphics |
| Mold Styles | |
| Type | Benefits |
| Photo-Etched (also referred to as Make-Ready) |
|
| Machine-Engraved |
|
Specifications
Our photo-etched dies are cost-effective and available with quick turnaround (often same to three day) service. We can also provide many highly custom options.
Formulations
Silicone Rubber Formulations |
Hardness |
Character Height |
Silicone Thickness |
Aluminum Thickness |
| Ultrasil (Red): High Heat Endurance |
40-90 durometers available in all formulations (Shore A)
Dual durometer (90/70) is also available |
0.035″, 0.065″, and .120” reliefs standard | 1/16” or 3/32″ is used for 0.035″ relief
1/8″ is used for .065″ relief |
1/16” and 1/8″ are standard
Deadsoft- Aluminum available; easily formed to set a contour |
| Thermosil (Brown): High Heat Endurance PLUS Enhanced Thermal Conductivity |
60-90 durometers available | 0.035″, 0.065″, and .120” reliefs, standard | 1/16” or 3/32″ is used for 0.035″ relief
1/8″ is used for .065″ relief |
1/16” and 1/8″ are standard
Deadsoft- Aluminum available; easily formed to set a contour |
Metal Dies
Commonly used for applications requiring an embossed appearance on flexible materials. Metal dies provide excellent heat transfer characteristics and durability. Additionally metal dies provide premium embossed visual impact, high durability, excellent heat recovery and compatibility with challenging substrates.
Additional Benefits
United Silicone metal dies also provide:
| Features | Benefits |
| Market-leading fine graphics | Detail as small as 4-point type on brass dies. |
| Die Finishing | Our die finishing services include hole drilling, matching dovetail and special trims. We can save you time by providing a completely “ready-to-use” die. |
| Magnetic Die Mounting Systems (Optional) | Provide for tool-less die changeovers in a matter of seconds while achieving up to 50% improvement in precision alignment performance. |
| Customer Service with Graphic Art Expertise | Our Customer Serve Reps are also graphic arts experts – eliminating “lost in translation” errors when it comes to manipulating and creating your artwork. |
Formats
United Silicone manufactures Magnesium, Brass and Steel dies with varying life cycles to best meet the performance, timeline and budget needs of each unique application.
| Shapes | |
| Type | Common Uses |
| Flat | Vertical stamping, peripheral and roll-on applications |
| Contoured | To precisely match a contoured part that requires decoration |
| Materials | |
| Type | Overview |
| Magnesium | A cost effective solution that is ideal for short run, quick-turn applications. |
| Brass | Less durable than steel but significantly more durable than magnesium. Brass dies are ideal for mid-sized production runs. Brass is also particularly well suited for metal die applications requiring contoured dies. |
| Steel | Ideal for high volume production runs on consistent parts. This is the most durable type of metal die and hence the most cost-effective for high volume applications. |
| Engraving | |
| Type | Benefits |
| Photo-Etched |
|
| Machine-Engraved |
|
(Average Die Life – Magnesium = X, Brass = 18X, Steel = 20X)
Specifications
Recommended Substrates
- Acetal
- Cardboard
- Leather
Magnesium Dies
- 16 Gauge – 11 Point – ¼” Magnesium
- Full Service Graphics – Numerous Art Formats
- Superior Etch Quality – .035” to .120” Relief
Steel and Brass Dies
- Made to required thickness and reliefs
Services - Die Finishing
United Silicone offers complete die finishing services for all of our silicone and metal dies. This service includes;
- Hole drilling
- Dovetail machining
- Specialty trims (vs. square or rectangle)
Services - Texturing
United Silicone´s unique texturing technique eliminates air entrapment inherent to hot stamping large, bold or solid areas. Our overlay of a matrix pattern to your artwork enables air to be vented through the face of your die utilizing a series of stamped dots, creating a network of fine graphics versus one solid area. This technique is achieved utilizing various dot sizes and spacing to best accommodate each application.
Silicone vs. Metal Dies
Which die material is best for my application?
Good question. Our application specialists would love to discuss your unique application with you and share our expert insights.
Here is a short answer- when selecting a die material, use the following guideline:
Rigid substrate →Flexible, silicone die
Flexible substrate→ Rigid, metal die
At a Glance:
Silcone Dies
- High impact pigment, metalic, holographic or prismatic impact
- More cost-effective than steel or brass
- Less pressure required
- Better conformity to slight surface variations
- No plastic deformation around artwork area
Metal Dies
- High impact pigment, metalic, holographic or prismatic impact
- Embossed visual effect
- Higher printing speeds
- Longer life
- May cause plastic deformation
Here is a much longer answer
| Rubber Dies | Metal Dies | |
| Materials Available | Various for specific applications – high temperatures, quick heat recovery, & high strength | Magnesium Copper Brass Steel |
| Average Die Life | Contoured – X Flat – 2X |
Magnesium – Y Copper – 4Y Brass – 18Y Steel – 20Y+ |
| Surface Variations (sinks) | Will Compensate | No Compensation for Sinks |
| Variation in Material Thickness | Will Compensate | No Compensation |
| Set-up Time | Quick Process | Lengthy Process |
| Pressure Requirements | 350 lbs. Per sq. inch (HS) 500 lbs. Per sq. inch (HT) |
1000 lbs. Per sq. inch |
| Temperature Requirements | 100F > Metal (approximately 300-400F) |
100F < Rubber (approximately 250-300F) |
| Dwell Time | 50% > Metal | 30% < Rubber |
| Decorative Finish | Foil/Transfer lays on top of substrate | Imbeds foil/transfer into surface |
| Price | Initial Set-up/Mold Charge Die Cost < Metal |
No Set-up/Mold Charge Magnesium – $ Copper – 2X $ Brass – 8X $ Steel – 10X $ |
| Substrates *indicates preferred material |
ABS Acetal Acrylic Polyamide (Nylon) Polycarbonate Polyethylene Polystyrene PVC – Plasticized PVC – Rigid* SAN* UV Coating Epoxy / Epoxy Coating Polyurethane Wood |
ABS Acetal* Acrylic Leather* Paper* Polyamide (Nylon)* Polycarbonate* Polyethylene* Polystyrene PVC – Plasticized PVC – Rigid SAN UV Coating* Epoxy / Epoxy Coating Polyurethane |
