Moulded Silicone Hoses

Moulded hoses, typically made from silicone, can be designed to almost any geometry. They offer an efficient and cost-effective solution when rigid pipes reach their limits in particularly tight radii and restricted installation spaces, or when standard hoses cannot be utilised. Moulded hoses are primarily characterised by their stable yet flexible properties. Fuel-resistant or chemical-resistant materials can be used in their manufacture. Additionally, NovaNox® produces custom-printed moulded hoses according to your specifications. We tailor our moulded hoses to your specific customer profile.

The properties of silicone enable diverse applications. In machinery, plant engineering, and vehicle technology, moulded hoses are used as fuel cell hoses, coolant hoses, or charge air hoses. In these applications, moulded hoses are constantly exposed to high temperatures, aggressive substances, vibrations, and pressure. Coolant hoses also transport a glycol-water mixture, requiring a robust and reliable moulded hose to ensure a constant cooling circuit.

Beyond the common applications mentioned above, NovaNox® moulded hoses can be used as intake hoses, radiator hoses, tank hoses, heater hoses, air conditioning hoses, wastewater hoses, turbocharger hoses, ventilation hoses, or extraction hoses.

Do you have a project requiring a custom moulded hose for a complex installation space? Then click here to book your free and non-binding initial consultation with our experts.

The manufacturing process for NovaNox® moulded hoses varies depending on the method. They can be produced by extrusion or winding. Vulcanisation permanently cross-links all materials, resulting in a dimensionally stable and sealed moulded hose unit. Nothing can penetrate the hose from the outside, nor can anything escape from it. This ensures that aggressive media can be safely transported from A to B, even under continuous pressure and temperature demands.

Mandrel Bending

Mandrel bending is used in both processes. For this, a custom-shaped steel or stainless steel mandrel is manufactured based on your geometry data. In extrusion, the hose core is extruded first. Subsequently, the fabric reinforcement is applied, and the hose cover is extruded. The blank is then pulled onto the mandrel tool with the corresponding geometry. This is followed by the vulcanisation of the moulded hose in an autoclave. Finally, the moulded hose is demoulded and cut to size. Extruded silicone hoses can be produced on a mandrel or mandrelless. They have a smooth or ribbed surface and are usually the more cost-effective alternative. For wound moulded hoses, the mandrel tool is first spirally wrapped with rubber bands. The bands are joined by vulcanisation. This is followed by demoulding and cutting of your moulded hose. Wound moulded hoses have a fabric structure on the outside and exhibit particular dimensional accuracy. These aspects make them the higher-quality alternative.

The strength and performance of NovaNox® moulded hoses depend on the material. They are typically made from high-quality, tested VMQ (silicone rubber) or EPDM (ethylene propylene diene monomer rubber). EPDM moulded hoses are resistant to aqueous media and are therefore particularly suitable for coolant applications. They are distinguished by their continuous temperature resistance from -50°C to +180°C (short-term up to +220°C). For much higher temperature requirements, NovaNox® high-performance silicone is employed. This material can withstand continuous temperature peaks of +250°C. Moulded hoses made from Styrene-Butadiene Rubber (SBR), however, are extremely cold-resistant and fire-safe, making them the optimal hose type for vehicle hydraulics and electrical insulation. Finally, moulded hoses made from Epichlorohydrin Rubber (ECO) are highly resistant to mineral oils and weathering and have a consistent temperature resistance from -40°C to +120°C.

All types of moulded hoses are resistant to chemicals, alkalis, and acids. High ageing resistance and weather resistance complete the profile of a robust moulded hose. A further quality feature of all types of NovaNox® moulded hoses is their elasticity. This allows for effortless compensation of constant engine vibrations, braking, and tensile movements. Due to their lightweight properties, NovaNox® moulded hoses also offer significant weight savings.

We can manufacture custom moulded hoses leveraging many years of experience in hose technology. NovaNox® moulded hoses are made from high-performance silicone. From simple to complex geometries, our modern manufacturing capabilities enable us to produce custom moulded hoses for every installation situation for manufacturers of machinery, plant engineering, and vehicles.

NovaNox® moulded hoses are therefore individually tailored to the customer's requirement profile. This approach also allows for the effective utilisation of particularly confined installation spaces. In machinery, plant engineering, and vehicle technology, NovaNox® moulded hoses can be used as fuel cell hoses, coolant hoses, charge air hoses, or fuel hoses. With our cross-sector expertise, we support our customers in new developments, further developments, and cost optimisations.

Are you interested in a custom moulded hose from NovaNox®? Then arrange a free and non-binding appointment with our experts now by clicking here.

NovaNox® coolant hoses are an extremely important component of engine cooling systems. They dissipate heat generated by the engine using a glycol-water mixture to prevent the engine from overheating. Coolant hoses are therefore exposed to high temperatures, aggressive substances, and strong vibrations, and must consequently be robust and reliably constructed. To meet these demands, they are typically manufactured from high-quality, tested EPDM (ethylene propylene diene monomer rubber) or VMQ (silicone rubber). NovaNox® coolant hoses are further enhanced by their elastic properties. This elasticity allows engine vibrations, braking, and tensile movements to be effortlessly compensated.

NovaNox® fuel cell hoses are a critical component for fuel cell systems. To ensure the process of converting chemical energy into electrical energy, various media and materials such as fuel, oxygen, and water must be directed into the fuel cell. In this context, the fuel cell hose must meet stringent requirements. Flexibility and resistance to temperature and chemicals are crucial here. NovaNox® has therefore made it its mission to offer high-quality and reliable fuel cell hoses.

The NovaNox® charge air hose can also function as a pressure or turbo hose. These are used in engines with compressors to establish the connection between the compressor and the combustion chamber. A charge air hose allows compressed air from the supercharger or turbocharger to be directed straight into the combustion chamber, ensuring better and more efficient combustion. This process increases engine performance and leads to significant fuel savings. The robust properties of NovaNox® hoses ensure that high temperatures, vibrations, and high pressure can also be compensated.