overmould

Overmoulding is a manufacturing process where a secondary material is molded over a pre-existing part, known as the substrate. This creates a single, integrated component with the properties of both materials. The substrate is typically made of a rigid material like plastic or metal, while the overmoulded layer is often a softer, more flexible material such as thermoplastic elastomer (TPE) or rubber.

The process begins with the substrate being placed into a mold cavity. Molten overmould material is then injected into the cavity, flowing around and bonding to the substrate. After cooling and solidification, the mold opens, and the finished overmoulded part is ejected.

Overmoulding offers several advantages. It can improve ergonomics and grip by adding a soft-touch layer to handles or tools. It can also enhance aesthetics by providing color or texture. Furthermore, overmoulding can increase durability by protecting the substrate from impact or environmental damage. It is also effective for sealing components, preventing ingress of dust or moisture.

Common applications for overmoulding include consumer electronics, automotive parts, medical devices, and sporting goods. For example, the rubber grip on a toothbrush or the soft-touch buttons on a remote control are often produced using overmoulding. This versatile technique allows for the creation of complex, functional, and aesthetically pleasing parts in a single manufacturing step.