Monday, June 20, 2016

The Basic Information About Overmolding

By Jerry Gray


In many applications, multiple materials need to be combined together into a single final product. Overmolding is one of the many process through which separate materials can be combined to make a single product. This process involves applying an overmold material over a substrate material to cover the whole or part of the substrate material. The resultant product is a single unit.

Substrates can take on a wide range of materials including metal, plastic, wood, glass, or ceramic. A substrate may also be a complete product in the form of electrical connectors, screws, threaded inserts, machined metal parts, or molded plastic parts. The substrate usually forms the first part of the final product, which is usually composed of chemically bonded and often mechanically interlocked materials.

Overmold materials are also of many different types, but they are usually plastic or rubber. The plastic or rubber is made into pellets before additives such as foaming agents, fillers, and colorants are added. There are compatibility issues between substrates and overmold materials, which makes it necessary to choose the overmold material wisely. In most cases, metals will work well with any kind of plastic.

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.

This activity is engaged in for several different reasons. The first reason is the enhancement of beauty and appearance. Color monotony is a product can be broken through the introduction of another material of different color. In fact, different materials with different colors can be introduced to achieve a final product with multiple colors. Secondly, areas of softness and flexibility can be introduced into rigid components using this process.

This process also helps to reduce or eliminate assembly line time. Instead of making separate parts and joining them later, one can just be overmolded onto the other and save time and resources. This activity also eliminates the need for using fasteners and adhesives on certain parts.




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