Moulding >
Overmoulding
What is Overmoulding?
Overmoulding involves at least two components being moulded on top of one another, often it is used to give a rubberised grip on plastic parts- such as a toothbrush handle.
Overmoulding is a two-step process that can be carried out with many thermoplastics and is an efficient way to manufacture multiple layers/colours/materials in one product. There are vast applications for overmoulded products in automotive, medical and many consumer goods.
What is overmoulding commonly used for?
Overmoulded components are widely used across domestic, military, industrial and medical industries. Within the home, cooking utensils, food containers and toothbrushes all commonly use overmoulding to give better grip, give a longer life to the product or improve chemical resistance.
Overmoulding is commonly used for medical devices as it gives a more hygienic surface, making them easier to clean than electronic components. An overmoulded exterior can encase electronics and wiring that could be dangerous or susceptible to spreading bacteria.
What plastics can be overmoulded?
Material compatibility is the most important aspect to consider when overmoulding. Whilst a mechanical connection (such as an undercut) can help adhesion between two plastics, a chemical adhesion is preferred. Not all plastics are able to form chemical adhesion between each other, which can then lead to peeling of the overmoulding over time.
Materials widely used in overmoulding as substrates include ABS, Polypropylene, and nylon. Often TPUs or TPEs are used to overmould onto these substrates. Silicone rubber can also be overmoulded onto thermoplastic and metal substrates.
Why Overmoulding?
Overmoulding allows customers more flexibility in their product design through the different textures, styles and colours of materials that can be used. Overmoudling can also increase the shock absorbency, durability and electrical resistance of a part, all without the additional costs associated with the manual assembly of the two parts.
Have a project in mind? For further information on overmoulding, a no obligation quotation and estimated lead times please contact us today.
For further information or a
no-obligation quotation simply
contact us today.
Projects
Frequently Asked Questions
What are the steps of overmoulding?
A base component or substrate is injection moulded, allowed to cure, then a second layer is moulded on top of the first to produce a single part. Overmoulding is often used for applications with rubber or TPE handles such as a toothbrush, or power tool to make the design more ergonomic and comfortable.
What materials are commonly used?
Material selection is crucial to the success of an overmoulded part as the substrate and overmoulded part must be made from compatible materials. The two parts must chemically and physically bond to make it durable.
Common materials used in overmoulding include ABS, HDPE and TPE for rubber-like grips.
What are the benefits/advantages of overmoulding?
- Overmoulded parts have a strong, durable bond that can withstand difficult environments, continued use, and water.
- The rubbery grip on parts often makes the part more comfortable and ergonomic.
- An overmoulding can improve the look of your product- by overmoulding in different colours or including a logo onto it.
How to know if overmoulding is right for my project?
If your project consists of different layers and materials, does not need to be disassembled and is made from thermoplastics then overmoulding might be just right for your project. With higher upfront costs than other forms of manufacturing, overmoulding is perfect for large production runs, but isn’t as well suited to low volume.
