Valpolymer: Our polyurethane processes
Valpolymer specializes in polyurethane processing and the combination of different manufacturing processes on different materials, offering complete, durable, and ready-to-use applications. High-performance elastomeric polyurethane is the company's flagship material, thanks to its exceptional versatility and adjustable hardness from 5 Shore A to 95 Shore A. Polyurethane blends suitable for contact with food and pharmaceutical products (compliant with US FDA 21 CFR and CE Regulation EN 10:2011) are available, as well as versions suitable for ATEX applications, accompanied by a specific Declaration of Conformity. We perform processing based on customer specifications and drawings for pieces ranging from 1g to 2500kg.
Material formulation
Our strength lies in our meticulous raw material purchasing process, which allows us to select only the finest materials available on the market. Furthermore, we are committed to directly formulating the materials ourselves, developing bespoke solutions that perfectly meet the specific needs of the finished product. This approach not only allows us to guarantee the highest quality, but also involves in-depth and targeted research into the product itself, resulting in competitive pricing compared to other offerings on the market. We believe this process is essential to meeting our customers' needs and maintaining high standards of excellence.
Production of Technical Articles in Polyurethane for Casting
Valpolymer manufactures technical parts in molded polyurethane, optionally integrated with metal inserts such as coated rollers, wheels, or bearings. The entire production process takes place in-house, from the analysis and design of the part to the final finish, ensuring maximum precision and quality. Upon request, polyurethane parts suitable for contact with food, for the pharmaceutical industry, or for ATEX environments are available, always accompanied by a Declaration of Conformity.
Polyurethane Coating of Metal Parts – Coated Rollers and Wheels
Valpolymer's main polyurethane processes include coating metal parts with elastomeric polyurethane, ideal for rollers, wheels, and bearings. The company can perform ribbon-coating on diameters exceeding 2,000 mm and lengths up to 8,000 mm. Certified coatings for food use or ATEX environments are available. Valpolymer can also manufacture the metal parts to be coated, offering a complete and integrated service.
Mechanical Machining on Polyurethane Parts
The company performs precision machining on polyurethane parts, such as coated rollers and wheels, ensuring extremely tight dimensional tolerances and high-quality surface finishes. These processes are essential for achieving high-performance and perfectly balanced components. The same techniques can also be applied to metals and engineering plastics, depending on the project's needs.
Waterjet Cutting on Polyurethane and Technopolymers
We have a waterjet that allows us to cut and shape polyurethane with high precision using a very high-pressure water jet. This system allows for clean and complex cuts, even on irregular or detailed shapes, without generating heat that could deform the material. Waterjet cutting is particularly useful for creating finished parts, custom shapes, and complex profiles, ensuring a smooth and precise finish ready for further processing or assembly.
Mechanical Machining on Metals
Valpolymer complements its polyurethane processing range with a department dedicated to mechanical processing of metal components. Molds for polyurethane casting and metal inserts, such as rollers, wheels, and other industrial components, are created for subsequent coating in polyurethane or rubber. The in-house integration of these processes allows us to offer customized, high-quality solutions, reducing production times and costs.
Cutting with circular saw and miter saw
We have a circular saw that allows us to make straight and precise cuts on sheets, polyurethane blocks, or other items. Thanks to the appropriate blade and speed adjustment, we can achieve a clean and uniform cut, reducing burrs or material deformation. We also have a miter saw that allows us to make highly precise cross-cuts and angled cuts. This tool is particularly useful for cutting to size and angles, ensuring piece stability and a smooth finish, while always working at controlled speed and pressure.
CNC and manual lathe work
We have a CNC lathe that allows us to perform polyurethane turning operations with high precision and repeatability. Numerical control allows us to automatically and accurately produce diameters, grooves, chamfers, and shaped profiles, ensuring consistent tolerances. We also have a manual lathe that allows us to machine polyurethane by performing turning operations such as diameter reduction, grooves, chamfers, and shaping. The operator manually adjusts the feed rate and cutting depth, allowing for direct control of the process and adapting the parameters based on the hardness of the material.
Working with pantograph
We have a pantograph that allows us to precisely machine and shape polyurethane parts, performing milling, engraving, and contouring, even on complex shapes. Thanks to the controlled movements and the use of suitable cutters, we can create detailed profiles and refined surfaces, maintaining excellent dimensional accuracy.
In addition to the direct processing of polyurethane parts, the pantograph also allows for the creation of molds and models, used for prototypes or for subsequent industrial processing, ensuring precision and repeatability.
Working with abrasive wheel
We have an abrasive wheel that allows us to shape, smooth, and finish polyurethane, eliminating imperfections and chamfering edges. Thanks to its high-speed rotation, the wheel allows for controlled material removal, achieving the desired shape and a more uniform surface. Working with moderate pressure and the appropriate grit prevents overheating of the material and ensures a precise finish.
Processing with controlled drilling
We have a controlled drill that allows us to make holes, countersinks, and small precision machining operations on polyurethane. By adjusting the speed and using suitable bits or cutters, we can remove material precisely and gradually, avoiding tearing or deformation. Working at a moderate speed and with controlled pressure, we obtain clean holes and even countersinks, ensuring a good finish on the piece.
Processing with a splitting machine
Our RUBBER15 splitting machine splits the thickness of our polyurethane sheets in two. Processing characteristics: maximum width (working width): 1500 mm maximum thickness: 50 mm minimum obtainable thickness: 2 mm Workable lengths: up to 7–8 metres with roller conveyors (high thickness/hardness materials) continuous processing with winders/unwinders for thicknesses less than 15 mm The machine is equipped with recirculating ball screws and brushless motors to guarantee cutting precision and stability.
Working with a 3D printer
Our 3D printer enables the creation of customized components, prototypes, and high-precision models, offering a print volume of up to 33.5 × 20 × 30 cm. This capacity allows for the production of both small technical details and medium-to-large objects in a single run, optimizing time and costs. Thanks to an XY resolution of 25 μm and an adjustable layer thickness between 25 and 300 μm, it is possible to obtain extremely defined surfaces and precisely reproduce even complex geometries and very fine details. The 250 mW laser technology also ensures high print quality and excellent detail definition. These features make the system ideal for rapid prototyping, the creation of aesthetic models, technical components, and design objects, guaranteeing maximum flexibility in the development and optimization of new products.
