Extremely Thin, Extremely Long Rubber Strips: Engineering Continuous Elastomer Solutions at Scale

Introduction

Producing rubber parts that are extremely thin and extremely long presents a unique set of engineering challenges. Tight thickness tolerances, consistent mechanical properties, and defect-free surfaces become increasingly difficult as part length increases. When those parts stretch into tens of meters rather than inches or feet, traditional manufacturing approaches begin to break down.

At Canyon Components, we recently completed a project involving FKM (Viton) elastomer strips measuring 0.7 mm (0.0276 in) thick and approximately 40 meters (131 feet) long. The application required tight dimensional control, uniform strength across the entire length, and clean handling suitable for downstream assembly. Achieving that combination demanded careful consideration of manufacturing method, material behavior, and post-processing.

There are several ways to produce parts like this. One common method is molding shorter sections and vulcanizing them together. While effective in many applications, that approach introduces joints that can act as mechanical weak points. For this project, we instead chose a continuous calendaring process, allowing the strip to be manufactured as a single, uninterrupted length. The result was a part with consistent strength, thickness, and performance across its entire span. Get in touch with the Canyon Components engineering team now!

In some configurations, we also laminated multiple thin strips together to create variable thickness zones using a specialty pressure-sensitive adhesive (PSA) tape that runs the full length of the part. This enabled precise thickness control without introducing discrete joints or steps.

This article explores how projects like this are engineered and manufactured. We will cover what rubber calendaring is, how it compares to vulcanized splicing, how PSA lamination works, and why industries increasingly require long, thin, continuous elastomer components. We will also discuss cleaning, spooling, and handling considerations that ensure these parts arrive ready for use.

The Engineering Challenge of Thin, Long Elastomer Parts

Rubber behaves very differently at small thicknesses than it does in bulk form. At thicknesses below 1 mm, even small variations in material flow, temperature, or tension can result in dimensional inconsistency. Over a 40-meter length, those small deviations can accumulate into unacceptable variation.

The main technical challenges include:

• Maintaining uniform thickness across the full length
• Avoiding localized thinning or neck-down
• Preventing internal stresses that cause curling or distortion
• Preserving tensile strength and elongation properties
• Ensuring surface cleanliness and defect-free edges

In applications where the strip functions as a seal, gasket, barrier, or flexible interface, even minor defects can lead to failure. This is why process selection is critical. Get in touch with the Canyon Components engineering team now!

Common Manufacturing Approaches for Long Rubber Strips

There are a few primary ways to manufacture long elastomer strips at this scale. In this post, we will focus on: segmented molding with vulcanization, and continuous calendaring. Each has advantages and limitations.

Molding and Vulcanizing Sections Together

One traditional approach is to mold shorter rubber sections, then join them end-to-end using vulcanization. Vulcanization chemically bonds rubber surfaces together under heat and pressure, creating what is often referred to as a splice.

This method offers flexibility in tooling and material selection. It is commonly used for conveyor belts, large O-ring cord, and certain gasket profiles. However, it introduces unavoidable discontinuities.

Even well-executed vulcanized joints typically have:

• Slight changes in hardness or elasticity at the joint
• Reduced tensile strength compared to the parent material
• Increased likelihood of failure under cyclic loading
• Visible joint lines that may interfere with sealing or aesthetics

For applications where uniform strength and thickness are critical, these joints become the limiting factor. In our project, any localized weakness was unacceptable. Get in touch with the Canyon Components engineering team now!

What Is Rubber Calendaring?

Calendaring is a continuous manufacturing process used to produce flat rubber sheets or strips with precise thickness control. Uncured rubber is passed through a series of heated rollers that compress and stretch the material into a controlled gauge.

Unlike extrusion, which pushes rubber through a die, calendaring rolls the material into shape. This rolling action allows for extremely fine thickness control and surface finish.

Key Characteristics of Calendaring

• Produces continuous, joint-free rubber lengths
• Excellent thickness uniformity, even at very thin gauges
• Smooth surface finish suitable for bonding or sealing
• Consistent material orientation across the entire length

For the project in question, calendaring allowed us to produce a single, uninterrupted 40-meter strip at 0.7 mm thickness, eliminating splice-related weaknesses entirely. Get in touch with the Canyon Components engineering team now!

Why Calendaring Was the Right Choice for This Project

By calendaring the strip as one continuous length, we achieved several critical benefits:

• Full mechanical strength across the entire part
• No stress risers or weak zones
• Uniform elongation and tear resistance
• Improved long-term durability under load
• Cleaner geometry for downstream assembly

In applications where the strip is tensioned, flexed, or compressed repeatedly, this uniformity translates directly into longer service life.

Calendaring also enabled tighter thickness tolerances than would be practical with segmented molding. Over 40 meters, maintaining 0.7 mm thickness required precise control of roller gap, temperature, and material viscosity. This level of control is a core part of Canyon Components’ calendaring capability. Get in touch with the Canyon Components engineering team now!

Vulcanization: What It Is and Why It Still Matters

Although we avoided vulcanized joints in this particular design, vulcanization remains a foundational process in rubber manufacturing and deserves explanation.

Vulcanization is a chemical crosslinking process that transforms uncured rubber into a durable elastomer. Heat and curing agents, typically sulfur or peroxide systems, create crosslinks between polymer chains. These crosslinks give rubber its elasticity, strength, and chemical resistance.

In splicing operations, vulcanization is used to bond two rubber surfaces together, effectively creating new crosslinks at the interface. While strong, the joint rarely matches the uniformity of a continuous part formed without interruption.

Vulcanization remains ideal for:

• O-rings and molded seals
• Rubber cord splicing where joints are acceptable
• Thick, low-stress parts
• Field-installed belt repairs

For ultra-thin, ultra-long strips under tension or compression, calendaring avoids the inherent compromises of splicing. Get in touch with the Canyon Components engineering team now!

Bonding Multiple Strips Together Using PSA

In one variation of the project, the application required variable thickness along the length of the part. Instead of stepping thickness through molding or machining, we laminated multiple calendared strips together.

This was accomplished using a specialty pressure-sensitive adhesive (PSA) tape that ran continuously along the full 40-meter length.

How PSA Lamination Works

• Individual rubber strips are calendared to precise thickness
• A continuous PSA layer is applied between strips
• The layers are bonded under controlled pressure
• The adhesive forms a uniform bond without curing heat

This approach offers several advantages:

• No localized joints or thickness steps
• Uniform bonding strength along the entire length
• Minimal added stiffness compared to thermal bonding
• Clean edges and predictable geometry

Unlike spot bonding or segmented lamination, continuous PSA bonding ensures the laminated structure behaves as a single composite part. Get in touch with the Canyon Components engineering team now!

Cleaning and Spooling for Shipment

Manufacturing is only part of the challenge. Extremely long, thin rubber parts must be handled carefully after production to avoid contamination, deformation, or damage.

For this project, the strips were:

• Cleaned to remove processing residues
• Inspected for thickness and surface defects
• Carefully tensioned to prevent stretching
• Spool-wound to maintain flatness
• Protected for transport and storage

Spooling is particularly important for long parts. Improper winding can introduce set or curvature that complicates installation. Canyon Components uses controlled spooling techniques that preserve geometry while allowing efficient shipping. Get in touch with the Canyon Components engineering team now!

Where Are Ultra-Long, Ultra-Thin Rubber Strips Used?

Applications for parts like this are more common than many engineers realize. Typical use cases include:

Industrial Sealing and Barrier Systems

Long rubber strips are often used as continuous seals or barriers in large-scale equipment where joints are unacceptable. Examples include environmental enclosures, large access panels, and process equipment housings.

Conveyor and Material Handling Systems

Thin elastomer strips can act as wear liners, guides, or dust barriers across long conveyor runs. Uniform thickness and strength are critical to prevent uneven wear.

HVAC and Architectural Systems

In large HVAC assemblies or building systems, continuous rubber strips are used for vibration isolation, air sealing, and moisture control. Spliced joints often fail prematurely in these environments.

Energy and Power Generation

In power plants and renewable energy systems, long elastomer barriers are used for insulation, sealing, and fluid management. Exposure to heat, moisture, and movement demands uniform material performance.

Specialty Manufacturing and Automation

Custom machinery often requires flexible interfaces that span long distances while maintaining precise tolerances. Continuous rubber strips provide a clean, repeatable solution. These could be used in the production of components for the aerospace industry, green energy, oil field, and more.

Why Canyon Components Is Suited for Projects Like This

Projects involving extreme length, thin gauge, and tight tolerances sit at the intersection of materials science and process control. Canyon Components specializes in that intersection.

Our capabilities include:

• Precision rubber calendaring
• Custom compound selection and testing
• PSA lamination and bonding
• Clean handling and spooling
• Tight tolerance inspection and quality control

We approach these projects as engineering problems, not catalog items. That means evaluating the entire system, from material chemistry to installation method, before recommending a manufacturing strategy. Get in touch with the Canyon Components engineering team now!

Material Options for Ultra-Thin, Ultra-Long Rubber Strips

Selecting the right elastomer is just as critical as choosing the right manufacturing method. When parts are only fractions of a millimeter thick and extend tens of meters in length, material behavior that is insignificant in short molded parts becomes amplified. Flexibility, tensile strength, creep resistance, chemical compatibility, and surface stability all influence whether a long strip will perform as intended or fail prematurely.

Below are the primary elastomer families Canyon Components works with for continuous calendared and laminated rubber strip applications, along with guidance on where each material excels.

FFKM (Perfluoroelastomer, Canrez®)

FFKM materials such as Canrez® or Kalrez® represent the highest tier of elastomer performance. While FFKM is most commonly associated with O-rings and critical sealing components, it can also be produced in thin profiles when chemical and temperature resistance is the primary driver.

Key characteristics for long, thin strips:

• Exceptional chemical resistance to acids, solvents, oxidizers, and aggressive process media
• Outstanding thermal stability, rated up to 335°C depending on grade
• Very low compression set and excellent long-term dimensional stability
• Inherently resistant to microbial growth and environmental degradation

Considerations:
FFKM is significantly more expensive than other elastomers and is generally reserved for applications where no other material will survive. Because of this, the production scales are typically much smaller, meaning that FFKM is typically not produced using calendaring. Instead, FFKM would typically be molded into smaller sheets.

FKM (Fluorocarbon, Viton® and Variants)

FKM is one of the most versatile materials for thin, continuous rubber strips. It offers an excellent balance of mechanical strength, chemical resistance, and processability.

Common FKM subtypes include:

• Type A: General-purpose chemical and oil resistance
• Type B: Improved chemical resistance with higher fluorine content
• GLT and GFLT: Low-temperature formulations with improved flexibility below freezing

Key characteristics for long strips:

• Strong resistance to oils, fuels, lubricants, and many chemicals
• Good tensile strength and tear resistance at thin gauges
• Excellent aging, ozone, and weather resistance
• Can be calendared to tight tolerances with consistent surface finish

Considerations:
Standard FKM becomes stiff at low temperatures, which may be a limitation for long parts that must remain flexible during installation. Low-temperature grades address this but at higher cost. FKM is not well suited for continuous steam or strong amine environments.

Silicone (VMQ, PVMQ, and Fluorosilicone)

Silicone elastomers are often ideal for extremely thin and extremely long strips due to their flexibility and process stability.

Subtypes include:

• VMQ: Standard silicone for general-purpose sealing
• PVMQ: Platinum-cured silicone for medical and food-grade use
• Fluorosilicone (FVMQ): Silicone with improved fuel and solvent resistance

Key characteristics for long strips:

• Exceptional flexibility, even at very low temperatures
• Stable calendaring behavior at thin gauges
• Clean surface finish suitable for bonding and lamination
• Naturally resistant to fungal and microbial growth

Considerations:
Silicone has lower tensile and tear strength than many other elastomers, which can be a concern in high-tension or abrasive applications. It also performs poorly in petroleum oils unless fluorosilicone grades are used.

NBR (Nitrile Rubber)

NBR remains a cost-effective and widely used option for long rubber strips when oil resistance and mechanical strength are required.

Key characteristics for long strips:

• Good resistance to petroleum oils and hydraulic fluids
• Higher tensile strength than silicone at comparable thicknesses
• Predictable calendaring behavior
• Available in a wide range of hardness values

Considerations:
NBR is more susceptible to ozone, UV exposure, and microbial attack than FKM or silicone. For long strips used in humid or outdoor environments, antifungal additives or protective coatings are often recommended. NBR also has limited high-temperature capability compared to fluoropolymers.

Neoprene (Chloroprene Rubber, CR)

Neoprene occupies a middle ground between NBR and EPDM-like materials and is often selected for balanced performance.

Key characteristics for long strips:

• Moderate oil and chemical resistance
• Good weathering, ozone, and flame resistance
• Better mechanical durability than silicone
• Stable calendaring characteristics

Considerations:
Neoprene does not match FKM for chemical resistance or EPDM for water and steam resistance. It is best suited for general industrial environments where exposure conditions are mixed but not extreme.

Polyurethane (PU)

Polyurethane elastomers are selected when mechanical durability is the dominant requirement.

Key characteristics for long strips:

• Very high abrasion and tear resistance
• Excellent load-bearing capability
• Strong resistance to extrusion and deformation
• Suitable for wear strips, guides, and protective barriers

Considerations:
Polyurethane is more difficult to calendar at ultra-thin thicknesses and has a narrower temperature range than silicone or fluoropolymers. It is also more sensitive to hydrolysis in hot, wet environments unless specially formulated.

Material Selection in Practice

For ultra-long, ultra-thin rubber strips, material selection often comes down to prioritizing one or two dominant requirements:

• Chemical exposure: FFKM or FKM
• Extreme flexibility: Silicone or fluorosilicone
• Oil resistance at lower cost: NBR
• Weather and general industrial use: Neoprene
• Abrasion and mechanical wear: Polyurethane

In some designs, Canyon Components combines materials through lamination or hybrid constructions, allowing engineers to place durability, flexibility, or chemical resistance exactly where it is needed along the length of the part. Get in touch with the Canyon Components engineering team now!

Conclusion

Extremely thin, extremely long rubber strips push conventional elastomer manufacturing beyond its comfort zone. While segmented molding and vulcanized splicing remain viable in many cases, they introduce structural compromises that are unacceptable in high-performance applications.

By calendaring a single, continuous strip, Canyon Components delivered a 40-meter, 0.7 mm thick elastomer part with full-strength continuity from end to end. By laminating strips using continuous PSA bonding, we also enabled variable thickness designs without joints or distortion.

These techniques allow engineers to rethink what is possible with elastomers at scale. When uniformity, strength, and precision matter across long distances, continuous calendaring and controlled lamination provide solutions that segmented methods simply cannot match.

If you are facing a sealing or elastomer challenge that seems too thin, too long, or too demanding for standard approaches, Canyon Components can help engineer a solution that works across the entire length. Get in touch with the Canyon Components engineering team now!