Benchtop Or Production LSR Metering & Mixing Systems?

Liquid silicone rubber (LSR) overmolding is widely used in medical device manufacturing and biotechnology, particularly where repeatability, cleanliness, and material control are critical.

One of the most common questions teams face isn’t whether to use LSR - it’s which metering and mixing system makes sense at each stage of development.

Benchtop and production-scale systems are not alternatives competing for the same role.
They are purpose-built tools for different phases of the same process.

Understanding how they complement each other is key to building a robust, scalable overmolding operation.

What an LSR metering & mixing system actually enables

Regardless of scale, every LSR metering and mixing system is responsible for:

• Accurate A/B component metering
• Consistent mixing at a controlled ratio
• Repeatable shot delivery into the mold

In med device and single-use overmolding, this consistency directly impacts:

• Bond quality
• Cosmetic finish
• Dimensional stability
• Long-term process reliability

The difference between benchtop and production systems is not capability, but context.

Benchtop LSR metering & mixing systems: precision for development and validation

Benchtop systems are designed to give engineering teams maximum control during R&D and early validation.

They are typically used for:

• Research and development
• Prototyping and early design iteration
• Process feasibility studies
• Pilot-scale and low-volume builds

Because benchtop systems use smaller material formats (such as cartridges rather than drums), they allow teams to:

• Work with minimal material waste
• Change materials or parameters quickly
• Validate processes before committing to volume

Their compact footprint and manoeuvrability make them well suited to:

• Lab environments
• Shared development spaces
• Early-stage overmolding trials alongside small presses or benchtop tooling

At this stage, success is measured by process understanding, not output volume.
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Learn more about our Benchtop LSR Metering/Mixing System here

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Production LSR metering & mixing systems: stability, throughput, and scale

Production-scale systems are where LSR overmolding becomes a repeatable manufacturing process.

They are designed for:

• Locked designs and validated materials
• Continuous, high-volume operation
• Integration with automation and tooling
• Long production runs with minimal variation

By drawing from larger material containers (pails or drums), production systems support:

• Higher throughput
• Reduced changeover frequency
• Improved material handling efficiency

When paired with a dedicated overmolding press, production metering and mixing systems enable:

• Stable cycle times
• Consistent shot-to-shot repeatability
• Scalable output without compromising quality

This is the stage where overmolding moves from “can we make this?” to “can we make this reliably, every day?”

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Learn more about our Production Scale LSR Metering/Mixing System here

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Why production systems deliver the real long-term value

While benchtop systems are essential early on, production systems are where teams realise:

• Lower cost per part
• Higher yield
• Reduced operator intervention
• Greater process confidence

In medical device and single-use manufacturing, this stability is often a prerequisite for:

• Process validation
• Technology transfer
• Scale-up into commercial production

For many teams, the production system - integrated with the right overmolding press - becomes the backbone of their overmolding operation.

The right way to think about scaling

The most successful overmolding teams don’t choose between benchtop and production systems - they plan for both.

A typical progression looks like this:

1. Develop and validate the process using a benchtop system
   Materials, ratios, tooling behaviour, and overmolding performance are refined with minimal waste.
2. Lock critical parameters
   Once consistency is proven, variability drops and confidence increases.
3. Transfer the validated process to a production-scale system
   The same principles, now delivered at volume - often alongside a production overmolding press.

This approach reduces risk, shortens time to scale, and avoids expensive rework.

A practical decision guide

A benchtop system is typically the right choice when:

• You are in R&D or early development
• Designs or materials are still evolving
• Flexibility and fast iteration matter most

A production system is typically the right choice when:

• The process is validated
• Output volume and repeatability are critical
• Integration with an overmolding press is required
• You are preparing for sustained manufacturing

Final perspective

Benchtop and production LSR metering and mixing systems each excel at what they are designed to do.

Benchtop systems enable learning and validation.
Production systems enable scale, stability, and long-term value.

Choosing the right system at the right time - and planning the transition between them - is what turns LSR overmolding into a reliable manufacturing process for medical devices and single-use assemblies.

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Learn more about our LSR Systems here

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