One system – many industries. Where does ELASTOSIL® VARIO truly prove its value?

In the world of technical materials, the search for a “one-size-fits-all” product is becoming increasingly rare. Instead, flexibility of solutions, the ability to tailor parameters to a specific process, and repeatable results are what truly matter. This is exactly the philosophy behind the ELASTOSIL® VARIO system — an RTV-2 silicone that does not impose a single set of properties, but allows them to be deliberately shaped.

VARIO is not a single silicone, but a modular, addition-cure system in which the user decides on the material’s hardness, elasticity, reaction time, and color. As a result, the same system finds application across many — often very different — industries, from prototyping and industrial design to electronics and advanced technical applications.

Flexibility that starts with hardness

The foundation of the VARIO system consists of two components with different hardness levels — VARIO 15 and VARIO 40. By mixing them in appropriate proportions, it is possible to achieve virtually any intermediate hardness within the Shore A 15–40 range. In practice, this means full control over the behavior of the finished mold: from very soft and flexible, ideal for complex undercuts, to noticeably stiffer, designed for longer production runs.

This represents a major advantage over traditional RTV-2 silicones, where each hardness is a separate product and every change in application requires starting testing from scratch.

Prototyping and industrial design – precision without compromise

In design studios and prototyping facilities, VARIO performs wherever precise detail reproduction and mold repeatability are essential. Zero linear shrinkage, high dimensional stability, and excellent flow properties allow even the finest surface structures to be accurately replicated.

Designers value VARIO because a single system can support different stages of a project — from soft test molds to more durable tools for short production series — without changing technology and without the risk of unexpected material differences.

Electronics and technical components – control and safety

Although VARIO is not a classic electronics potting silicone, it is widely used in the production of molds, fixtures, and auxiliary components employed in assembly processes. Flexible silicone molds are often used for component positioning, assembly testing, or the production of repeatable insulating elements.

Thanks to its addition-cure chemistry, VARIO does not release by-products during curing, which is crucial in environments sensitive to contamination — such as electronics, optoelectronics, and precision mechanical assemblies.

Industrial molds – durability and service life

In industrial applications, VARIO is used to produce molds for polyurethane and epoxy resins, technical plaster, architectural concrete, and wax. The ability to match hardness to the cast material has a significant impact on mold longevity and the quality of finished parts.

Softer variants facilitate demolding of complex geometries, while harder ones provide dimensional stability and mechanical resistance in cyclic production.

Craft, small-batch production, and creative applications

VARIO is increasingly finding its way into craft workshops and artistic studios, where not only technical performance but also aesthetics and process control matter. The ability to color the silicone with FL pigments, color stability, and predictable curing behavior make this system well suited for short production runs of decorative, design, and functional items.

One system – a real technological advantage

What truly sets ELASTOSIL® VARIO apart is the fact that it does not force the user to adapt to the material. Instead, the material adapts to the process, the application, and the operator’s experience. The ability to adjust hardness, reaction time (thanks to different catalysts), color, and mechanical properties makes VARIO a long-term solution — not a one-off choice.

For companies, this means simplified logistics, fewer products in inventory, and greater process consistency. For users, it translates into working comfort, repeatable results, and genuine control over the final outcome.