There are many applications that require several materials to be combined together to make a single product. One of the processes through which several materials are combined to make a single item is referred to as overmolding. This process involves a substrate material over which overmold material or materials are applied to partially or fully cover it. Once the overmold material has been applied, it forms a single item with the substrate.
Substrates are of a wide variety of materials including metals, plastics, wood, ceramic, and glass. In some cases, substrates are complete products such as electrical connectors, threaded inserts, screws, molded plastic parts, and machined metal parts. The final product is composed of the substrate as the first part and the overmold substance applied on top. The two are chemically bonded and usually mechanically interlocked.
Various types of overmold materials are in existence today. Rubber and plastics have however stood out as the most commonly used overmold materials. During the process, small pellets are made of the overmold substance before addition of additives like foaming agents and colorants. Careful choosing is necessary because of compatibility issues. Metals and plastics always work well together because they form a strong bond with each other.
However, plastic and rubber substrates pose compatibility issues with overmold plastics or rubber. Manufacturers of overmold materials usually publish a chart indicating what substrates the materials is compatible with and to what extent. Depending on the kind of product being made and its specific application, the compatibility chart should be studied carefully. Overmold material that produces the strongest bond and strength between the substrate and itself should be used.
Several different industries and settings have application for this process. Various products are made using this process. Some of the products include screw drivers, casters, cans, tools, toothbrushes, laptops, and handgrips. There are a few versions of this process in use, including plastic over plastic, plastic over metal, rubber over metal, and rubber over plastic.
During the procedure, part or the entire substrate is put inside an injection molding equipment. The substrate material is then applied with shots of overmold material onto, into, around it. After the shots are applied, time must be allowed for the overmold substance to cool down and solidify in a process called curing. The final product is a single, joined component.Introducing interlocking mechanisms is advised to make the bonding stronger.
There are many different reasons why people engage in this process. The first reason is to enhance the aesthetics of a product. This process helps to break up color in a product by introducing another color. The final product can have multiple colors, which make it to look better. The second reason is for introducing soft or flexible areas in a rigid part. For instance, rubber parts may be introduced to a plastic or metal handle to make handling easier.
Another importance of this process is reducing or eliminating assembly line time. Time and resources are saved by avoiding the production of two separate components and joining them up later. A single component is made and overmold material applied over it. Also, the use of adhesives and fasteners is avoided through this process.
Substrates are of a wide variety of materials including metals, plastics, wood, ceramic, and glass. In some cases, substrates are complete products such as electrical connectors, threaded inserts, screws, molded plastic parts, and machined metal parts. The final product is composed of the substrate as the first part and the overmold substance applied on top. The two are chemically bonded and usually mechanically interlocked.
Various types of overmold materials are in existence today. Rubber and plastics have however stood out as the most commonly used overmold materials. During the process, small pellets are made of the overmold substance before addition of additives like foaming agents and colorants. Careful choosing is necessary because of compatibility issues. Metals and plastics always work well together because they form a strong bond with each other.
However, plastic and rubber substrates pose compatibility issues with overmold plastics or rubber. Manufacturers of overmold materials usually publish a chart indicating what substrates the materials is compatible with and to what extent. Depending on the kind of product being made and its specific application, the compatibility chart should be studied carefully. Overmold material that produces the strongest bond and strength between the substrate and itself should be used.
Several different industries and settings have application for this process. Various products are made using this process. Some of the products include screw drivers, casters, cans, tools, toothbrushes, laptops, and handgrips. There are a few versions of this process in use, including plastic over plastic, plastic over metal, rubber over metal, and rubber over plastic.
During the procedure, part or the entire substrate is put inside an injection molding equipment. The substrate material is then applied with shots of overmold material onto, into, around it. After the shots are applied, time must be allowed for the overmold substance to cool down and solidify in a process called curing. The final product is a single, joined component.Introducing interlocking mechanisms is advised to make the bonding stronger.
There are many different reasons why people engage in this process. The first reason is to enhance the aesthetics of a product. This process helps to break up color in a product by introducing another color. The final product can have multiple colors, which make it to look better. The second reason is for introducing soft or flexible areas in a rigid part. For instance, rubber parts may be introduced to a plastic or metal handle to make handling easier.
Another importance of this process is reducing or eliminating assembly line time. Time and resources are saved by avoiding the production of two separate components and joining them up later. A single component is made and overmold material applied over it. Also, the use of adhesives and fasteners is avoided through this process.
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