A complete breakdown of the overmolding injection molding

Overmolding is a very beneficial industrial process that many product developers rely on for large and quality production runs. This production process is an important type of injection molding. This type of production method can be used to make everyday consumer products. It comes with many benefits which product manufacturers capitalize on for large revenue.

What is overmolding?

Overmolding is a production process that features multiple injection steps. In this moulding process, two components or more are intermolded together to create a single unique product. Overmolding can also be known as multiple-material molding. Another name for this production process is 2 shot/2k, which is derived from the German word, “Zwei komponenten.” It is called do because it is a 2-step production process.

 

The process of overmolding

The overmolding injection molding process is a two-phase production process that requires the use of two components or substrates. The first component is made to go through the mold. It is then given enough time to cure. Materials used got overmolding injection are usually plastic substrates. Next, a second material is directly moulded on top of the first component, which helps to form one solid product. The overmolding injection process is used commonly in the production of plastic parts that have rubber handles. The overmolding injection mold process is used extensively in the toothbrush production industry. The process involves the formation of a base material to create the plastic handle. It then goes on to create a top rubber layer. This gives the toothbrush an improved grip for a more efficient use.

 

Materials that are commonly used for overmolding

Overmolding is a highly useful industrial production process that involves the ride use of suitable plastic materials. The materials used for this production method include:

• TPE (Thermoplastic Elastomers)
• SI (Silicone)
• PMMA (Acrylic)
• PEI (Polyetherimide)
• PE (Polyethylene)
• PEEK (Polyether Ether Ketone)
• ABS (Acrylonitrile Butadiene Styrene)
• PBTR (Polybutylene Terephthalate)
• TPU (Thermoplastic Polyurethane)

 

The benefits of the overmolding injection molding process

There are many benefits to overmolding and they are:

Manufacture products with multiple parts/colours:  It is a process whereby you can easily manufacture products by simply using multiple parts. This same industrial process can also be used to manufacture products with multiple colours for enhanced aesthetics.

 

Reduced labour costs: This type of injection molding process also involves the use of less labour, which in turn helps to reduce the cost of production. Compared to other methods of production, it is relatively more efficient and cost-effective. Since it helps to reduce the cost of production, manufacturers rely on this production model to enhance profitability.

 

Eliminate product assembly: This molding process minimizes the work needed during product assembly as the parts are manufactured at the same time on top of each other. This usually results in a much more durable and stronger general design.

 

Increase product aesthetics: The overmolding injection process can be used to enhance product aesthetics and it allows the use of multiple colours and multiple layers. This is evident in modern power tools, toothbrushes, clippers, and cooking utensils.

 

Perfect for large production runs: The overmolding process is the perfect method of manufacturing that is best suited for large production runs.

Excellent functional benefits: Overmolding can be used to provide both thermal and electrical insulation for commercial products.

 

Improve product handling properties: Overmolding can be used to improve product handling for personnel to increase productivity. It enables overlaying whereby tools and kitchen utensils are fitted with handles that enhance grip during use.

 

Strong material bonds: Overmolding can be used to create strong bonds between materials.

 

Shock reduction: Overmolding as an industrial process can be used to reduce shock and vibrations in commercial products. This production process involves the addition of extra external materials onto products to enhance their ability to withstand vibrations and shocks.

 

Improve resistance to chemicals/ultraviolet light: This process is also useful in helping materials withstand chemicals and ultraviolet light. In industrial applications, it is used to add suitable materials to products to provide these properties.

Increase product durability: Manufacturers depend on this production process to increase the durability of products.

 

The drawbacks of the overmolding injection mold process

The overmolding injection production process also comes with its drawbacks. These include:

Excess upfront investment: The production tools used in the overmolding injection process are quite complex. Since it takes more time and expertise to build, it costs a lot of money.

Features the use of large and complex machines:  The overmolding injection process is a production method that involves the use of large machine plants. It often involves machines that have complex operational modes.

 

When should you choose the overmolding injection process?

The overmolding production process is an important manufacturing method that can be used for a wide range of manufacturing processes. It is an elaborate technology that is only suitable for certain production processes. You can choose overmolding in the following instances:

• When you want the finished piece to be made of rubber and/or thermoplastics.
• When you want to produce a product made up of multiple layers, colours, and/or materials.
• When you will have to manufacture the second layer and the substrate.

 

Important applications of overmolding

Manufacturers rely on the process of overmolding to produce products for a wide range of industries. It can be used in different application areas:

Consumer goods: Overmolding is a process that can be used in the production of various plastic products with multiple features. It is a very popular production method that can be used to produce a wide range of consumer goods.

 

Used in the automotive industry: Overmolding is used widely in the automotive industry to produce aesthetic two-tone car interior components like dash panels, doors, knobs, handles, and so many controls. It is used to produce various vehicle components.

 

Applied in the beauty industry: The process of overmolding is used extensively in the beauty industry. They can be used to produce attractive cosmetic packages. With this production process, designers can create products that have custom packaging with multiple colours and unique surface textures. In the beauty industry, this production process works when used to produce perfume bottles, makeup brushes, and compacts.

For more about a complete breakdown of the overmolding injection molding,you can pay a visit to Djmolding at https://www.djmolding.com/overmolding/ for more info.