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Manufacturing Process of Butterfly Rubbers

Manufacturing Process of Butterfly Rubbers

Rubbers that are used all over the world such as Tenergy and Dignics have been produced in Butterfly TEC, where we comprehensively research, develop, and manufacture our rubbers and blades.
The pimple-in rubber is the most used type of rubber in table tennis. Its structure consists of two layers; a sheet directly touching the ball when hitting it and a sponge attached to the sheet, as shown in the figure.
 ≫Click here for more information about the types of rubbers.

Manufacturing Rubber Process: Figure 1 - Pimple-in Rubber Structure

Rubber Manufacturing Process

We are introducing the main processes involved in manufacturing Butterfly rubbers. Our rubber manufacturing is carried out meticulously, with more processes and inspections shown below.

Manufacturing Rubber Process: Figure 2

 

Let’s take a look at typical scenes from the actual manufacturing process in our factory.

Kneading ingredients

Add substances and other ingredients to the natural rubber material. Knead until the gradients are mixed evenly. Top sheets and sponges have a similar process to be manufactured.

Manufacturing Rubber Process: Figure 3

Manufacturing Rubber Process: Figure 4

Manufacturing Rubber Process: Figure 5

Manufacturing Rubber Process: Figure 6

Vulcanization → Top sheet inspection

Place the top sheet material well kneaded into a mold and put pressure on it while applying heat. Inspect the top sheet surface strictly, one by one with the human eye to make sure there are no alien substances or dirt.

Manufacturing Rubber Process: Figure 7

Manufacturing Rubber Process: Figure 8

Manufacturing Rubber Process: Figure 9

Manufacturing Rubber Process: Figure 10

Sponge slicing → Sponge punching

Slice the original materials of the sponge into the specified thicknesses, such as 2.1 and 0.5. Punch out a sliced sponge to a size slightly larger than the finished rubber product.

Manufacturing Rubber Process: Figure 11

Manufacturing Rubber Process: Figure 12

Manufacturing Rubber Process: Figure 13

Manufacturing Rubber Process: Figure 14

Weight sorting→ Sponge inspection

Operate a high-precision measuring robot and strictly inspect the sponge thickness of punched-out sponges. Also, inspect to make sure no large holes or dirt on the sponge surface exist.

Manufacturing Rubber Process: Figure 15

Manufacturing Rubber Process: Figure 16

Manufacturing Rubber Process: Figure 17

Manufacturing Rubber Process: Figure 18

Rubber application → Rubber punching

Apply an environmentally friendly water-based glue by machine, combine the rubber top sheet and sponge, and punch out to the size of the finished product. After punching, laser-print the production lot number and sponge thickness on the sponge’s surface to manage the manufacturing history. Inspect the rubber top sheet and sponge surfaces again as a final inspection.

Manufacturing Rubber Process: Figure 19

Manufacturing Rubber Process: Figure 20

Manufacturing Rubber Process: Figure 21

Manufacturing Rubber Process: Figure 22

Packing

Auto-package the finished rubbers one by one by machine. Ship worldwide with cardboard boxes of 180 sheets of rubbers, each consisting of inner boxes of 6 sheets.

Manufacturing Rubber Process: Figure 23

Manufacturing Rubber Process: Figure 24

Promotion Video

Manufacturing Rubber Process: Takayuki Tetsuka

Takayuki Tetsuka
Butterfly Rubber Production Dept.

If the bounce or touch of a product is not constant, it would be fatal for elite players who live in a world of extreme competition, it might also prevent players who are still trying to obtain new skills from improving. That is why our staff members dedicate themselves every day to manufacturing so that we can provide the same quality in every single product for our customers.

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