• Project Overview

    A customer required a custom plug to mask a square bore with rounded corners during powder coating. Standard plugs could not achieve a reliable seal on the non-standard geometry.

    • Application: Powder coating, 200°C cure cycle
    • Geometry: Square with rounded corners, 40 x 24 x 24 mm
    • Tolerance: ±0.1 mm
    • Quantity: 500 pcs per production run
  • Project Cost Breakdown

    After reviewing the drawing and confirming process requirements, we provided the following quote:

    • Engineering: USD 500 one-time design and engineering fee
    • Tooling: USD 850 one-time mould cost, held at no charge for the lifetime of the project
    • Unit price: comparable to standard low-volume production parts
    • Production delivery: 4 weeks from design confirmation
  • Custom Silicone Plugs

    • Mask, seal, and protect bores, holes, ports, and internal threads.
    • Available in tapered, hollow, pull-tab, flanged, dual-purpose, and handle designs.
  • Custom Silicone Caps

    • Protect studs, bolts, pins, protrusions, tube ends, and external threads.
    • Available as washer caps, terminal caps, vented caps, and other custom designs.
  • Custom Sleeves & Covers

    • Protect shafts, pipes, profiles, machined surfaces, and complex features.
    • Ideal for protection, masking, and sealing applications in coating, surface treatment, and PCB manufacturing.
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  • Surface Treatment Processes

    Protect critical areas during coating, plating, anodizing, and painting processes with high-temperature silicone masking solutions engineered for consistent performance across multiple production cycles.

    Typical Applications

    • Powder coating
    • E-coating / KTL
    • Anodizing
    • Electroplating
  • Electronics Manufacturing

    Precision silicone masking solutions for electronics and PCB manufacturing, protecting connectors, contact points, and critical surfaces during conformal coating and selective coating processes.

    Typical Applications

    • PCB masking
    • Connector protection
    • Selective coating areas
    • Electronics assembly
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From Requirement to Series Supply

Step 1

Application Review

We review your drawing, part sample, or technical specification. The evaluation covers the area to be masked or protected, process type, temperature exposure, chemical environment, and required masking zone.

Based on these requirements, we develop an initial component concept.

Step 2

Concept Development

Based on the application review, we define the component geometry, silicone grade, fit concept, and insertion and removal features.

The design considers operating conditions, compression behaviour, reusability, and additional requirements such as venting, colour coding, or ergonomic handling.

Step 3 (optional)

Qualification Parts

Prototype or qualification parts are produced to validate fit, handling, and process performance. This confirms that the component meets production requirements before series tooling and supply are released.

Qualification parts are available approximately 14 days after drawing approval.

Step 4

Production Supply

After successful qualification, the component moves into repeatable series production. Documentation, part identification, and supply planning are managed to support long-term production continuity.

Minimum order quantities remain flexible to support both pilot projects and series production.

Series tooling is typically completed within 3–4 weeks. Once tooling is approved, standard production batches can be supplied within 2–3 days after order release.

Engineering Criteria

Engineered around the variables that determine performance

High Temperature Reliability

Our silicone components are manufactured from high-quality, heat-resistant silicone designed for demanding industrial masking applications.

Rated for use up to 250°C / 480°F, the material provides reliable performance across repeated process cycles, including powder coating, e-coating, anodizing, plating, and other high-temperature applications.

Compression, Sealing & Fit

Each component is engineered for controlled compression, reliable retention, and clean removal.

Masking performance is determined by the interaction of geometry, wall thickness, material hardness, and process conditions, not dimensional fit alone.

Dimensional Tolerance & Critical Surfaces

Masking geometry is developed around drawing specifications, tolerances, and the exact boundaries of the protected surface.

Critical masking zones are defined before finalizing component geometry.

Insertion, Removal & Operator Ergonomics

Handles, tethers, pull tabs, and ergonomic features can significantly reduce operator handling time per part.

Insertion and removal requirements are considered during the design phase, especially for high-volume production environments.

Venting & Pressure Relief

In e-coating and other dipping or immersion processes, trapped air and pressure build-up inside sealed cavities can lead to plug ejection or coating defects.

Venting and pressure-relief features can be integrated where process conditions require them.

Color Coding & Visual Identification

Optional color coding through silicone compounds or geometry differentiation helps production teams identify the correct masking component for each application.

This reduces misapplication risk on high-mix production lines and multi-variant manufacturing environments.