We need to thermoform the outer skin into the shape of a front and back side breast form. This is done in a heated mold and vacuum.
After the application of the silicone gel nipple inside the front skin and the completion of its curing cycle , we can then form a closed envelope by welding together front skin and back skin alongside its perimeter. Yet, we leave a small orifice on the top of the envelope through which we shall fill in the liquid silicone gel later..
Now we need to prepare the silicone gel. After polymerizing and end capping the siloxane intermediate, we need to purify the resulting silicone gel polymer from volatile components by filtering and a following distillation process at 200 o C under high vacuum.
The result is a viscous, high purity, transparent, 100% silicone liquid with a content of 99,95% of non volatiles, a silicone polymer which is useful for medical applications. In order to form a silicone gel suitable for a breast forms, the polymer needs to be cross linked by means of a “cross linker compound” and a platinum catalyst.
To “cure” the polymer to a gel, we now admix the cross linker/Platinum compound in an adequate ratio to accomplish a life like mobility and consistency.
The silicone polymer, cross linker and platinum compounds are now inspected by quality control and released for manufacturing.
Now we fill the liquid cross linker compound and platinum catalyst containing silicone gel into the skin..
After curing the silicone polymer to a gel, the breast forms are being conducted to the finishing department.
Finally, the filling orifice is closed, the excess skin trimmed, and after a final inspection, the breast forms are ready to be packed into master cartons for warehousing and shipping.