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Overmolding is a one-of-a-kind injection molding technology that allows different materials to be seamlessly combined into a single part or product. It usually consists of a stiff plastic base component coated with a thin, malleable rubber-like thermoplastic elastomer (TPE) external layer or other materials. Read More…
OvermoldingOvermolding is a process that is very similar to the standard injection molding process except for the fact that it combines two materials.
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It is manufactured using either a single-shot (insert molding) or two-shot (multiple-shot molding) technique. The procedure is repeated twice, making it an excellent choice for applications requiring long-term durability and dependability.
Standard injection molded components are often weaker and less durable than overmolded components. Overmolding produces goods like push buttons and keys that are heavily used and must survive this abuse while remaining legible.
Overmolding is essentially the same injection molding process repeated twice, with a much lower margin for error. To construct the fundamental shape of the final product, the base material is pumped into the mold first.
This mold leaves room for the second material to be injected. The two components harden and produce the final product once the second ingredient is introduced into the mold. However, any mistake in one of these stages necessitates re-doing the entire procedure.
Overmolding is a technique for layering materials on a product to offer strength, longevity, or just an aesthetic advantage. Overmolding, like injection molding, is entirely based on the customer's demands, requirements, and specifications. This is because custom-made goods are simple to create and design during the mold design phase.
Injection molding is extremely popular because it allows things to be mass manufactured quickly and cheaply.
Advantages of Overmolding
Better product performance: Improved product performance is the main motivation to develop and manufacture a product or part utilizing overmolding. TPE (thermoplastic elastomer) is an excellent material for generating a soft, non-slip grip for many devices where tactile sensitivity is desirable and essential, such as medical instruments. In addition, by decreasing shock, vibration, and noise, a TPE surface can act as an environmental barrier to safeguard a product and increase its shelf life.
Shelf appeal improved: Because TPE may be utilized to produce an aesthetically appealing surface, overmolding helps a product stand out from the competition. TPE is available in a variety of hues and can be tailored for a variety of finishes. Clear TPE surfaces can be overmolded on patterned or bespoke substrates to carry a corporate logo, message, or operating instructions.
Production costs are lower: Overmolding is unusual in that it increases value in multiple ways while lowering production costs. Overmolding minimizes the number of processes in the manufacturing process. It can, for example, eliminate the requirement for injection molding and assembly of components (such as gaskets or bumpers) and secondary finishing processes in the automotive industry (priming, painting, or coating).
Applications of Overmolding
Automobile Manufacturing: Insert molding is often used to make electrical sensors, gears, fasteners, and other automotive parts made of a combination of metal and plastic or rubber. Solid two-tone interior components, such as door and dash panels, handles, knobs, and different controls, are made with overmolding. Insert molding is a technique that certain motors and batteries go through.
Medicine Industry: Plastics are easier to sterilize than electrical and computer components. The medical industry relies largely on insert molded and overmolded parts. Defibrillators, medical wires, and wiring are frequently enclosed in plastic via insert molding to preserve the delicate interior components while making the finished device easier to clean. Insert molding is often used to construct medical devices that are intended to be placed inside the body, such as pacemakers. Insert molding is also used in producing a range of internal imaging camera equipment, such as those used to perform endoscopies and colonoscopies.
Electrical Engineering: Insert molding a rubber exterior to electrical cables makes them safer and even waterproof in certain situations. Manufacturers commonly wrap electrical components in rubber to make goods like smartphone and computer chargers safer for users. Multiple wires are sometimes enclosed in a single sheet of rubber, while at other times, wires are separated and distinguished using contrasting colors, such as blue and red.
Industry of Beauty: To make cosmetics packaging more appealing, overmolding and insert molding are commonly employed. Designers can use them to create personalized packaging with different surface textures and colors. Overmolding or insert molding can be used to construct products like compacts, beauty brushes, and perfume bottles.