Yield Rate Rises from 85% to 95%! Betely Self-Adhesive Silicone Rubber: A Real-World Mass-Production Case Study for the 3C Industry

2026-05-21 15:19

In promoting our self-adhesive silicone rubber, we have come to increasingly recognize that what customers truly seek is not merely a simple specification sheet, but rather a comprehensive bonding solution that is practical, scalable for mass production, and delivers high yield rates.

Recently, the Betely team, in collaboration with a 3C electronics industry client, successfully addressed the challenges of adhesion risks and production‑scale stability associated with self‑adhesive silicone rubber. This project’s successful implementation vividly demonstrates Betely robust capabilities—driven by the seamless integration of business, technology, and quality to deliver end‑to‑end, collaborative solutions.

The actual pain points faced on-site by the customer

During the production of silicone rubber‑coated components, this customer has long been plagued by two major issues:

● The adhesion strength between silicone rubber and the PC substrate exhibits significant variability, frequently resulting in delamination defects during production.

● Traditional processes rely on primer coatings to facilitate adhesion, but the volatile organic compounds they emit fail to meet the workshop’s environmental compliance standards.

The customer’s core requirement is clear: without altering the existing molding process, achieve a mass-production solution that eliminates the need for primer application, boosts production efficiency, and ensures consistently stable yield rates.

Bettley’s three-pronged synergy delivers a one-stop solution to break the deadlock.

1. Rapid on-site presence at the business front end, precisely identifying and capturing requirements.

Our business team promptly conducted on-site visits to the customer’s production facilities, systematically identifying key process milestones and product failure issues. They collected test samples, as well as critical parameters such as compound hardness, flow characteristics, molding temperature, and cycle time, and coordinated in advance with the technical team to ensure seamless collaboration, thereby shortening the overall solution‑development timeline.

2. Targeted R&D: dual optimization of formulation and process

Leveraging the robust capabilities of Betely Dongguan R&D Center, the technical team has precisely tuned the density of self‑adhesive silicone rubber functional groups and the vulcanization compatibility window for PC‑specific substrates. Following multiple rounds of fine‑tuning and validation, they have achieved the desired performance:

● Under vulcanization conditions of 120–130°C, 200 seconds, and a material thickness of 2 mm, the bond strength remains consistently above 4 MPa.

● Optimizes the compatibility between rubber compounds and metal molds, significantly reducing sticking and mold‑locking issues.

● No primer is required throughout the entire process, meeting both workshop environmental standards and aligning with the existing production rhythm.

3. Comprehensive quality control throughout the entire process, ensuring consistent batch-to-batch stability.

The quality team, in collaboration with customers, has jointly developed customized incoming‑material inspection standards, batch‑sample retention protocols, and a regular pull‑test verification mechanism. At the same time, dedicated process controls have been implemented on the production line to rigorously manage manufacturing details at the source, ensuring consistent performance across multiple batches and minimizing significant quality fluctuations.

Commercialization and mass production outcomes

The customer completed the solution migration and end-to-end validation in just two to three weeks, smoothly transitioning into the stable mass-production phase.

● Customer feedback indicates that the production yield has improved from the original 85% to 95%.

● Preliminary calculations indicate an overall process cost reduction of approximately 30% (eliminating the primer, reducing defects, and minimizing rework);

● Completely eliminates the primer application step, successfully passing all internal tests for environmental compliance, odor, and volatile organic compounds.

At present, this mature solution has been progressively rolled out across multiple product lines and new projects for our customers.

Betely self‑adhesive silicone rubber boasts core advantages that extend far beyond the single benefit of eliminating the need for a primer. What truly sets us apart and drives differentiated competitiveness is our end‑to‑end, system‑level service capability—customizing formulations, optimizing processes, and rigorously managing quality—tailored to customers’ real‑world production environments. This enables seamless implementation and stable mass production, saving our clients time and effort.

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