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Overmolding and Insert Molding Design Guide
A guide to two-material molding and bonding options with plastics, elastomers, and metal inserts
Overmolding is an injection molding process that allows an additional layer of resin to be added to an existing molded part to provide a combination of characteristics that no single material can provide. One of the most common applications is to add a soft, functional, hand-friendly layer of rubber-like material,typically a TPE (thermoplastic elastomer) over a hard substrate. Another is to change or enhance the appearance or “cosmetics” of a part by overmolding material of a different color or finish to it. Overmolded materials can be found on anything from medical devices and hand-tools to toothbrushes and as gaskets and seals within assemblies.
Insert molding is an easy way to integrate threaded metal inserts into components like this plastic drone propeller.
As a manufacturing process, overmolding can provide excellent adhesion between different materials and eliminate the need to assemble materials by hand. Because the process can be automated to varying degrees it can be quite cost-effective. And, by reducing the complexity of assembly, it can help reduce costs and accelerate products and devices to market. But most important, it can greatly enhance the range of material characteristics available to a product developer.
There are two primary methods for overmolding—two-shot molding and pick-n-place molding, with the former using a single production mold while the latter uses two molds.
Material selection for overmolding can be complicated. Substrate and overmold resins can complement one another, but to be effective, they have to be compatible. Choices vary not just with the application of the overmolded part, but also with the method being used to produce it. Because process and outcomes are more complex for overmolding than for single-shot injection molding, it is helpful to seek input from resin experts when selecting materials.
LCW Manufacturing
China
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