Silicone R&D verification and testing

Q: How is the flame retardant grade determined?

The flammability tester tests silicone to the UL94 standard and determines grades such as V0, V1 and V2, used for flame retardant silicone products in new energy, electrical and industrial control equipment.

From raw material composition, formula ratios, mechanical properties, environmental ageing and electrical performance through to bond reliability, appearance and dimensions, testing runs across R&D and volume production rather than as a final spot check.

Only a data-backed plan can be called stable in production

Silicone formulas and composite processes carry many variables: material composition, filler ratio, cross-link state, interface treatment and molding parameters. Adjusting by experience alone means problems often surface only at the batch stage; with test data, the direction can be judged at the planning stage and deviations located during sampling.

Our laboratory covers verification from raw material to finished part, supporting silicone formula iteration, optimisation of composite processes and product reliability confirmation. It provides the data basis for developing and stably producing silicone over metal, plastic and PCBA composite parts.

This page describes testing capability directions. Test items, applied standards and acceptance criteria for a specific project are confirmed at the planning stage according to customer requirements and the product application.

Silicone material testing and reliability verification in the lab — Mechanical property and bond strength testing are the base items for verifying a composite part, and one of the bases for batch acceptance.

Testing capability

Six equipment groups and the items they cover

Each group answers a specific question: is the material right, is the performance sufficient, does it survive the environment, is it electrically safe, how long does the surface last, and are dimensions and internal quality acceptable.

Composition & Formula

Material composition and formula analysis

Raw material verification, formula ratio analysis, material traceability and contamination testing, controlling raw material quality at the source.

FTIR spectrometer: Molecular spectrum analysis identifies the silicone base and additive system, distinguishing standard silicone, fumed-silica compounds, medical-grade and food-grade grades, preventing material mix-ups, and checks whether fillers and modifiers in the formula meet specification.
Thermogravimetric analyser (TGA): Measures mass change at high temperature, thermal decomposition temperature and residual ash to analyse thermal stability, filler ratio and temperature limits.
Rotational rheometer: Tests viscosity, viscoelasticity, cure rate and flow behaviour of liquid and milled solid silicone, used to optimise injection, compression and potting parameters.
Solids and volatiles tester: Measures solids content, small-molecule volatiles and migration to support low-odour, low-migration and food or medical grade control, avoiding yellowing, fogging and odour risks.
Elemental spectrometer: Tests heavy metals and restricted additives for RoHS, halogen-free and environmental compliance control.

Mechanics

Physical and mechanical properties

Covers tensile, tear, rebound, hardness, compression set and bond strength.

Universal tensile tester: Tests tensile strength, elongation at break, tear strength and peel strength; verifies the peel force of silicone over metal, plastic and PCBA, confirming the composite strength achieved by nano bonding and primer pre-treatment.
Shore durometer (type A / D): Covers the Shore 0–90A range: type A for soft silicone, wearable parts and seals, type D for high-hardness wear-resistant structural parts.
Rebound tester: Tests deformation recovery rate and permanent set on high-rebound, fast-rebound and slow-rebound silicone, quantifying cushioning, damping and fatigue resistance.
Compression set tester: Simulates long-term compression, measuring residual deformation of seals and load-bearing structures to verify long-term sealing and compression stability.

Weathering

Environmental and ageing tests

Simulates high and low temperature, damp heat, salt spray, UV and ozone to accelerate verification of long-term reliability.

Programmable temperature and humidity chamber: Covers temperature cycling starting from -60 °C and constant-humidity damp heat conditions (the upper temperature limit is confirmed with the equipment and project requirements), testing silicone stability and overmold interface strength so that no cracking or delamination occurs under temperature change.
UV and ozone ageing chamber: Accelerates outdoor ultraviolet and ozone attack to test ageing, yellowing and cracking resistance.
Salt spray chamber: For silicone over metal parts, tests corrosion protection of the metal insert and the sealing protection of the silicone layer.
Thermal shock chamber: Fast alternating high and low temperature to assess stress cracking resistance of dissimilar-material composites and to detect delamination caused by different thermal expansion coefficients.

Electrical

Electrical insulation properties

For silicone and electronic composite products: insulation, withstand voltage, anti-static and flame retardant performance.

Dielectric strength tester: Tests breakdown voltage and insulation strength to verify the insulation protection of electronic overmolded and potted products.
High-resistance insulation tester: Measures volume and surface resistivity to determine insulation or anti-static grade, for precision electronics, industrial control equipment and security accessories.
Flammability tester: Tests flame retardant performance to the UL94 standard, determining grades such as V0, V1 and V2.

Surface & Durability

Wear life and surface performance

Verifies abrasion, sweat and rub resistance and the stability of surface processes, matching the service life of coating, screen printing, in-mold transfer and laser marking.

Multi-function abrasion tester: Simulates repeated rubbing and sweat exposure, testing the adhesion of inks and coatings and verifying that printed and coated graphics do not come off or crack.
Surface roughness tester: Measures the micro-level flatness of molded and coated surfaces to judge mold etching, polishing and coating results.
Key life tester: Runs millions of press cycles on silicone keys and touch parts to verify rebound stability and structural fatigue life.

The available surface routes are listed under surface finishing.

Dimension & Defect

Precision dimension and appearance inspection

Protects dimensional accuracy and molding yield for precision small parts, irregular structures and electronic composite parts.

2.5D optical image measuring instrument: Measures irregular contours, thin-wall structures, hole sizes and spacing to an accuracy of ±0.001 mm.
Industrial endoscope: Inspects hollow parts, sealed cavities and internal overmold structure to find voids, short shots, bubbles and internal cracks.
Precision thickness gauge: Multi-point wall thickness measurement to control thickness consistency in compression, injection and potting molding.

System strengths

A closed-loop R&D and testing process

Most silicone factories only have basic hardness and tensile testing. We close the loop: where the data comes from, where it is used, and how it returns to volume production.

01
Raw material analysis

Confirms base material type, additive system and environmental compliance, preventing material mix-ups.
02
Formula performance verification

Verifies the formula item by item against mechanical, rebound, temperature and safety requirements.
03
Process parameter optimisation

Adjusts parameters using rheology and molding data while verifying interface bond strength.
04
Reliability and life verification

Confirms long-term performance with weathering, electrical, abrasion and dimension data, as the acceptance baseline for volume production.

For silicone over metal, plastic and PCBA composite products, the test and verification plan can be tailored per project, using data to pre-empt off-spec material, bond failure, insufficient weathering and short service life. Interface treatment routes are described under bonding to other materials.

FAQ

R&D and testing questions

Which tests can you run?

Six groups: material composition and formula analysis (FTIR, TGA, rotational rheometry, solids and volatiles, elemental spectroscopy); physical and mechanical properties (tensile, tear and peel strength, hardness, rebound, compression set); environmental ageing (temperature and humidity cycling, UV and ozone, salt spray, thermal shock); electrical insulation (dielectric strength, insulation resistance, UL94 flammability); wear life and surface performance (abrasion, surface roughness, key life); and precision dimension and internal defect inspection (optical image measurement, industrial endoscope, thickness gauging).

What is the temperature range of the thermal tests?

The programmable temperature and humidity chamber covers temperature cycling starting from -60 °C as well as constant-humidity damp heat conditions, simulating severe cold, high temperature and humid environments to verify silicone stability and interface strength. For materials rated for long-term use at 400 °C level, the high-temperature verification conditions and method are confirmed per project.

How is the flame retardant grade determined?

The flammability tester tests silicone flame retardant performance to the UL94 standard and determines grades such as V0, V1 and V2, used to verify flame retardant silicone products for new energy, electrical and industrial control equipment.

How is overmold bond strength verified?

Peel strength is measured on a universal tensile tester to verify the interface bond between silicone and metal, plastic or PCBA. A thermal shock chamber then assesses the stress cracking resistance of the composite structure under alternating temperatures, detecting delamination caused by different thermal expansion coefficients.

Where is the test data used?

For silicone formula iteration, optimisation of composite process parameters and product reliability verification, and as the basis for quality control during volume production. Each composite product can have a test and verification plan tailored to the project, and confirmed data can serve as the acceptance baseline for the production batch.

Need performance or reliability verified?

Send us the operating environment, performance requirements and acceptance criteria. We will confirm the test items and acceptance basis first, then arrange formula and process verification.

Request verification