Friction experienced by seals over time generates heat and accelerates wear, potentially leading to damage and even critical failures. Traditionally, this can only be mitigated through rigorous and frequent maintenance. However, this brings its own challenges: increased maintenance costs, extended equipment downtime, and reduced operational efficiency.
Today, we introduce the MouldTex project—an initiative aimed at enhancing sustainability in manufacturing processes by reducing friction in dynamic elastomeric seals.
This advanced manufacturing method involves a one-time application of laser technology directly onto the mold surface, creating micro-protrusions instead of micro-cavities. This allows microtextured patterns to be transferred from the mold to the seal component during molding. Additionally, advanced simulation software ensures proper mold filling and precise component geometry.
A specialized methodology has been developed for seal design using laser microtexturing on critical contact surfaces. This technique significantly reduces friction at the interface, while the microcavities also serve dual functions: they retain lubricant and trap wear debris, further enhancing the seal’s performance and lifespan.
Initially, the project faced a major challenge—limited knowledge of optimal microtexture designs. Early development relied on a trial-and-error approach, which eventually evolved into a numerical optimization strategy. With time, researchers succeeded in using advanced modeling software to determine the ideal patterns for various contact scenarios and specific operational conditions of each elastomeric sealing application.
Another significant milestone was the development of a micrometer-precision laser system, capable of engraving hierarchical microtexture patterns directly into mold surfaces. Alongside this, a robust inline optical inspection system was designed and implemented, ensuring consistent surface quality and pattern accuracy during production.
The result? A reduction in friction of over 20%, and a significant decrease in wear, which in many cases doubles the component’s service life.
In this context, industries such as automotive, wind energy, and aerospace—among others—stand to benefit greatly from adopting this cutting-edge technology. The microtexturing process developed under the MouldTex project represents a substantial leap toward more sustainable, efficient, and durable sealing solutions.hnologies to deliver efficient, durable, and environmentally responsible sealing solutions.