The more companies learn about overmolding, the more they want to use this special injection-molding technology to add value to their product lines. Not only does it improve functionality and performance, it lowers total production costs—that’s pretty rare these days.
So, what is overmolding?
Using a one-shot or two-shot process, a thin layer of TPE (thermoplastic elastomer) is overshot onto the hard plastic substrate of the product. This exterior layer is what creates the soft-touch grip for so many products, like toothbrushes and tool handles. But it has lots of other properties that also add value to the final product—it can reduce shock and vibration, dampen sound, provide electrical insulation, boost chemical/UV resistance, be an effective barrier against oxygen and moisture, and perhaps most importantly, create a wide range of colorful, stylish exteriors that catch the consumer’s eye.
More consumers are demanding this look and feel for the personal-care products, tools, electronics, sports equipment, medical devices, etc. they purchase. As a result, overmolding applications continue to expand across a wider range of products. The availability of this technology also gives product engineers more creative freedom in designing attractive and functional products that will keep them on the leading design edge of their markets.
Not every injection-molder can overmold, however; it requires specialized equipment, extensive training, and precise control of multiple variables throughout the production run—even the slightest variations can affect quality, so skilled operators are essential.
Overmolding engineers must have a deep knowledge of material chemistry and know how different types of TPE and substrates interact under varying pressure and temperature conditions. This field of knowledge is also rapidly expanding—suppliers are continuously engineering new blends with expanded characteristics such as chemical resistance, UV resistance, hardness, scratch resistance, clarity, heat resistance, and UL standards. Kaysun Corporation has a vast material science database it has accumulated from hundreds of previous projects and our engineers stay on top of the latest developments in new materials.
It can take some time getting overmolding just right, but it’s worth it—this one- or two-step process delivers products of such high quality that the need for some downstream finishing operations is eliminated, which saves time and money and gets products into the marketplace faster.
Of course, this is common knowledge at Kaysun. We have perfected this process through extensive investments in technology and training; this is why top global companies like Rockwell Collins (defense and aerospace) and Smith’s Medical (health care) rely on Kaysun.
Learn more about Kaysun’s overmolding capabilities by downloading our white paper or contacting us. We’re the perfect place to start—and finish—your injection molding project.