Overmoulding

Overmoulding is a manufacturing process where a thermoplastic or thermoset material is molded directly onto another part, typically made of plastic or metal. This process involves placing a pre-formed substrate part into a mold cavity and then injecting molten plastic around it. The molten plastic fuses with the substrate, creating a single, integrated component. Overmoulding is often used to enhance the functionality, ergonomics, or aesthetics of a product.

The primary advantage of overmoulding is its ability to combine different materials with unique properties into a single part. For example, a rigid plastic housing can be overmoulded with a soft, grippy material to improve handling and comfort, such as in tools or electronic devices. It can also be used to add features like seals, gaskets, or insulation directly onto a component, eliminating the need for separate assembly steps. This can lead to cost savings, improved product performance, and increased durability.

Common applications for overmoulding include automotive components, consumer electronics, medical devices, power tools, and sporting goods. The process requires precise control over temperature, pressure, and cooling to ensure good adhesion between the overmould material and the substrate, and to prevent damage to either component. Material selection is critical, as the overmould material must be compatible with the substrate and capable of adhering to it effectively.