Overmoulding Explained
Overmoulding is a manufacturing process where one material is molded over or around another material, creating a multi-layered or composite part. This process is commonly used in injection molding and involves a primary material (called the substrate) being combined with a secondary material (called the overmold) to enhance functionality, aesthetics, or ergonomics.
Key Features of Overmoulding
Materials Used:
- Substrate: Typically a rigid material like metal, hard plastic, or thermoplastic.
- Overmold: Usually a softer, more flexible material such as rubber, silicone, or thermoplastic elastomer (TPE).
Applications:
- Adding grip or texture to handles (e.g., tools, toothbrushes).
- Creating seals for water-resistant or airtight parts.
- Providing vibration damping or insulation.
- Improving appearance or colour contrast.
Advantages:
- Combines the properties of two materials into one part.
- Reduces assembly steps and potential weak points from adhesives or fasteners.
- Improves durability, ergonomics, and aesthetics.
Types of Overmoulding:
- Two-Shot Overmoulding: Uses a single machine with two injection units to sequentially mold the substrate and overmold.
- Insert Molding: Inserts a preformed substrate into a mold before injecting the overmold material.
Example Products
- Power tools: Hard plastic body with soft rubber grips.
- Medical devices: Flexible seals or grips over a rigid plastic frame.
- Consumer electronics: Rubberized buttons or edges for shock absorption.
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