Custom Molded Rubber and Plastic

We design, prototype and build production molded parts


Specialized rubber and plastic molded components

We offer custom mold design, prototyping and manufacturing for rubber and plastic parts for automotive, agricultural and industrial OEMs, Tier 1s and aftermarket companies. We’ll assist you from the early design stages until product is in hand and in use.

Beyond our rubber and plastic material expertise, we’ll advise on custom mold features and finishes like  slip-coating, flocking, adding clips, adding steel, aluminum or wire carriers, cutting, notching, splicing, bonding molded corners, adding adhesives and more.

Plastic Materials:


Nylon is a synthetic thermoplastic fiber. It melts easily when exposed to heat, varying luster, resistance to insects, fungi, molds and chemicals and is less absorbent than other materials. Nylon is used as a fabric or mechanically. In its solid form it is very wear resistant and used to build low to medium stress gears, bearings, bushings, and other mechanical parts. As a fabric, it was used as a replacement for silk in clothing, parachutes, stockings, toothbrushes, etc.


Polycarbonates are a group of thermoplastic polymers that are easily molded and commonly used. They are temperature and impact resistant and have excellent electrical properties. This polymer is a clear plastic with a slight yellow discoloration. Processing is more difficult due to high melting temperatures. Used in tube shaped extrusions, bottles, glass lenses, compact discs and typical sheet applications such as computers, etc.

Polyethylene, LDPE and HDPE

Polyethylene is a thermoplastic. The most common polymer in plastics is polyethylene. It is cheap, flexible, durable, and chemically resistant. There are two different types LDPE and HDPE. LDPE: polymer strands are entangled and loosely organized, so it’s soft and flexible. It was first used to insulate electrical wires, but today it’s used in films, packaging material, wraps, bottles, disposable gloves and garbage bags. LDPE stands for low-density polyethylene based off the ability to float in a mixture of alcohol and water. HDPE: When ethylene is polymerized in the presence of various metals, a tighter, denser, more organized structure was produced called high-density polyethylene. HDPE is a harder plastic with a higher melting point than LDPE, and sinks in an alcohol-water mixture. HDPE is used for containers, plumbing, and automotive fittings.

Polyethylene Terephthalate (PET or PETE)

Polyethylene Terephthalate (PET or PETE) is a thermoplastic polymer is used in creation of synthetic fibers. PET is less permeable than other low-cost plastics since it is often paired with aluminum to reduce permeability. This makes it a popular material for making carbonated drink bottles. PET is available in transparent, opaque and white coloring. PET is strong and abrasion resistant, and is used for making mechanical parts, food trays, and other items that require impact resistance.

Polymethyl Methacrylate (PMMA) acrylic

Polymethyl Methacrylate (PMMA) acrylic, also known as acrylic glass or plexi glass, are well known for their use in paints and synthetic fibers, such as “fake furs”. In bulk form they are very hard and more transparent than glass and also easier to stretch. PMMA is often sold as glass replacements. This material has strong impact resistance, however dissolves easily in a variety of common solvents. PMMA is processed using injection molding, compression molding or extrusion.

Polypropylene (PP)

Polypropylene (PP) is a thermoplastic polymer. The various forms of polypropylene have different melting points, hardnesses, clarity, impact resistance. PP was first created as a cheaper version of Polyethylene. It is commonly shaped using injection molding techniques. Polypropylene is commonly used in packaging, textiles, car trim, battery cases, bottles, tubes and bags.

Polytetrafluoroethylene (Teflon)

Polytetrafluoroethylene (Teflon) is a thermoset plastic. The polymer is a nonstick, heat-resistant, strong, and resistant to many chemicals and has a nearly frictionless surface. PTFE, better known as “Teflon”, is mainly used as a protective coating to metal surfaces and is created by exposing a polyethylene container to fluorine gas. Teflon is most commonly used in the “nonstick” frying pan.

Polyvinyl Chloride (PVC)

Polyvinyl Chloride (PVC) is a thermoplastic. A plasticizer liquid is added to material to make original material soft and moldable. PVC has numerous properties including various colors or clarity, flexibility, flame resistance, compatibility with other additives, electrical resistance, impact strength and resistant to bad weather conditions also resistance to grease, oil and chemicals. PVC is commonly used for pipes and plumbing because it’s durable, resistant to corrosion, and less costly than metal pipes. It is also the least environmentally friendly plastic. Extruded PVC is used for sealing items such as garage doors or refrigerators and for structural components of vehicles.

Thermoplastic Elastomers

Thermoplastic Elastomers (TPE’s) are flexible materials that have the characteristics and performance abilities of rubber but are processed like a plastic. With the ability to be stretched to at least twice its size at room temperature and still return to its original length upon release of stress, it has a longer life and physical range than most alternate materials. TPE’s are classified into 6 traditional classes; Styrenics (S-TPE’s), Copolyesters (COPE’s), Polyurethanes (TPU’s), Polyamides (PEBA’s), Polyolefin Blends (TPO’s), and Polyolefin Alloys (TPV’s). In addition to these, there are approximately 3 new TPE entrants including Reactor TPO’s (R-TPO’s), Polyolefin Plastomers (POP’s), and Polyolefin Elastomers (POE’s).

Rubber Materials:

Ethylene Propylene Diene Monomer (EPDM)

EPDM rubber is ideal for outdoor applications because of its excellent resistance to ozone, oxidants, and severe weather conditions. Other outstanding characteristics include excellent color stability, heat resistance, and dielectric qualities. EPDM offers many of the advantages of neoprene, at a lower cost. The resilience and tensile strength of EPDM rubber is slightly lower than both natural rubber and polyisoprene. EPDM is not recommended for applications involving petroleum derivatives. EPDM is generally attacked by mineral oils, solvents, and aromatic hydrocarbons. EPDM has a tendency of being conductive when carbon black is mixed in the compound. Most black color rubber compounds are mixed with carbon black. EPDM is not recommended as an electrical insulator. Product examples using EPDM include glass run channel weatherstripping, vehicular seals, trim seals, glass sealing weatherstripping and belt weatherstripping.

Natural Rubber

Natural rubber is excellent as a general-purpose elastomer: it offers a good balance of superior tear strength, high resilience and tensile strength, good abrasion resistance, and good flexural qualities at low temperatures. Natural Rubber should not be used where it will be exposed to chemicals or oil. Also, it does not stand up well in outdoor use where it is subjected to oxygen, sunlight, ozone, and temperature extremes. Product examples using natural rubber include latex gloves and nursing equipment.

Neoprene (CR)

Neoprene is durable and water resistant. It also has good resistance to oils, hydraulic fluids, grease, and ozone attack and can be used to create a cushion and a barrier against damage to something being housed within it. Neoprene is noted for a unique combination of properties, which has led to its use in thousands of applications in diverse environments.  Neoprene withstands fluctuations in temperature but fairs poorly in consistently low temperatures and will self extinguish a flame.  Neoprene is a popular material for wetsuits, electrical insulation and car fan belts. Its resistance to chemicals makes it suitable for industrial applications such as gaskets, hoses and anti-corrosion coatings. It can also provide an effective base for adhesives, as well as an effective noise insulator in power transformer applications.

Nitrile (NBR)

Nitrile rubber is resistant to petroleum oils and aromatic hydrocarbons and is also highly resistant to mineral oils, vegetable oils, and many acids. In addition, nitrile has good elongation properties as well as adequate resilience, tensile and compression set. Because of its cost, this elastomer is not usually recommended for applications where oil resistance is not a major problem. Where oil resistance is required, the cost is justified. NITRILE RUBBER is generally attacked by ozone, ketones, esters, aldehydes, chlorinated and nitro hydrocarbons.


Santoprene thermoplastic rubber is a family of high-performance elastomers which successfully combine performance characteristics of vulcanized rubber, such as flexibility and low compression set, with the processing ease of thermoplastics. Because of the longer life of Santoprene in both extreme hot and cold environments, the material is often preferred over the use of rubber. Santoprene rubber fits into the middle of the cost and performance spectrum of both thermoplastic and thermoset rubbers. The abrasive resistant material can be blow molded, teleformed, or injection molded with great ease. Along with the fact that the material is so easy and cost efficient to produce, Santoprene also can be recycled. Santoprene rubber has the environmental resistance equivalent to general purpose EPDM rubber compounds, while fluid resistance is comparable to general purpose polychloroprene rubber compounds. This unique combination of environmental resistance and fluid resistance provides a thermoplastic rubber suitable for a broad range of applications including:

  • Appliances: pump gaskets, supports, boots, hose connectors, plugs, sump boots, baffles.
  • Automotive: rack-and-pinion boots, air ducts, cable covers, bushings, windshield spacers, tubing, grommets, gaskets, body scals for windows and doors, body plugs, weather stripping, lamp covers, suspension dust covers, air bag doors.
  • Building and construction: glazing gaskets, weather stripping for doors and windows, expansion joints, setting blocks.
  • Business machines: rollers for printers, computer feet, vibration isolators.
  • Electrical/electronic: molded connectors, power transmission and distribution components, linemen’s accessories, mining cable, control cable, power-limited circuit cable, submersible cable, coiled cords, flexible cords.
  • Fluid delivery: plumbing seals, filter and pump seals, hose and tubing, pipe seals.
  • Food contact: diaphragms, valve seals, closure seals, hose and tubing.
  • Hardware: caster wheels, tool grips, industrial rollers.
  • Medical devices: closures, gaskets, stoppers, plunger tips.
Silicone Rubber (VMQ)

Silicone rubber is ideally suited for many automotive, appliance, electrical/electronic, and aerospace custom rubber requirements where high resistance to both high and low temperature extremes are required.  Silicone has inherent resistance to ozone attack, ultraviolet light, corona discharge, moisture, and chemical attack. Silicone also has good tensile strength, elongation, compression-set, and abrasion resistance.  Cost can be a limiting factor where extreme temperature resistance is not essential. Unreinforced silicones also have lower tensile strengths than most other members of the elastomer family. Silicone rubber is generally attacked by many solvents, oils, concentrated acids, dilute sodium hydroxide. Product examples using silicone include exhaust hoses.

Styrene-butadiene or styrene-butadiene rubber (SBR)

SBR rubber is a versatile elastomer with above average flexibility, resilience, and abrasive resistance. SBR has good weathering characteristics and is resistant to mild-to-moderate chemicals, organic acids, and alcohols. SBR is easily formulated with high styrene resins to produce tough, hard rubber applications. Compounding with other elastomers greatly improves its oil and solvent resistance.  It can be compounded to provide very fine abrasion, wear, and tensile qualities. SBR can be readily substituted for natural rubber in many applications with significant cost savings.   Like natural rubber, SBR offers little resistance to oils and chemicals. SBR must be specially compounded to provide resistance to ozone, sunlight, and heat.   Product examples using SBR include vehicle mats. Product examples using SBR include glass window sealing weatherstripping.


Viton rubber is a relatively new addition to the elastomer family; Fluoroelastomers resist a wide variety of corrosive fluids at elevated temperatures while retaining their mechanical properties. Other features include resistance to weathering, ozone, oxygen and flame, good tensile strength, resilience, and low compression set. Unlike many of their counterparts, Viton fluoroelastomers retain their basic properties at extremely high temperatures. Fluoroelastomers are still undergoing extensive development and their excellent mechanical stability under severe operating conditions making them an ideal component where the cost can be justified.

Fairchild Industries, Inc.
475 Capital Drive
Lake Zurich, IL 60047
Phone: 847.550.9580
Fax: 847.550.9585

Fairchild Industries