Overmoulding is an advanced plastic moulding technique that combines different materials into a single component, offering a blend of properties that single-material products can’t match.
From ergonomic tool handles to waterproof electronic casings, overmoulding is quietly transforming the objects we use daily.
Read on to learn precisely what overmoulding is, how it works, and how you can take advantage of it.
What is Overmoulding?
Overmoulding is an advanced two-stage plastic injection moulding process that fuses multiple materials into a single, cohesive component.
You first create a base substrate, which is then encased or partially covered by a second material.
The result? Products that boast a useful combination of different properties – think rigid structures with soft-touch exteriors or chemically resistant cores with vibration-dampening outer layers.
Applications of Overmoulding
Overmoulding is versatile, hence why it’s been adopted across a broad spectrum of industries. Here are some examples:
Electronics: Ruggedised cases for electronics that preserve function in difficult environments
Medical devices: Ergonomic surgical tools with enhanced tactile feedback and sterilisation-friendly materials
Automotive: Luxurious interior components that combine structural integrity with soft-touch comfort
Industrial equipment: Durable machine controls that withstand harsh environments while ensuring operator comfort
Why Choose Overmoulding?
Overmoulding allows for products that are both functional and appealing. Imagine a phone case with a tough core, soft, grippy exterior, or tools with rigid bodies and comfortable handles.
The initial tooling costs can be higher than traditional moulding methods. However, it often pays off in the long run. You’ll likely save on assembly costs and end up with a higher-quality product that stands out from the competition.
Of course, there are some challenges to consider. Material compatibility is crucial – get it wrong, and your product might not hold together. Complex designs can also be tricky to execute well, particularly when coupled with the shrinkage that can occur post-moulding with certain thermoplastics.
The Overmoulding Process at BEC Group
At BEC Group, we’ve honed our overmoulding process to a fine art, ensuring each project benefits from our wealth of experience and cutting-edge technology.
We cover every stage of product development:
- Collaborative design: We engage in in-depth consultations to fully grasp your vision and requirements and work with you
- Material engineering: Our experts select and test material combinations to achieve optimal performance
- Precision tooling: Our master toolmakers craft bespoke mould tools that ensure consistent, high-quality results
- Advanced production: Utilising state-of-the-art injection moulding systems for precise, repeatable outcomes
- Rigorous quality assurance: Comprehensive quality control regimes guarantee every part meets exacting standards
If you’re curious to learn more about overmoulding, please contact us today. We’ll be more than happy to discuss your project and how overmoulding from BEC Group can contribute to its success.
