Overmoulding Cables, Inserts, PCBs, Electronic overmoulding, low pressure overmoulding and connector overmoulding.
Overmoulding is a more complex injection moulding process, by which an additional layer of plastic can be added to an existing component to enhance its performance or appearance.
The overmoulding process offers benefits that include ‘soft touch’ finishes, ergonomics, two colour aesthetics, brand identification and functionality such as strain relief, vibration dampening and ingress protection.
We continue to invest in additional equipment to cope with growing demand for overmoulding. We have a specialism in mouldings which incorporate sensitive PCBs and other electronic components where it is imperative that the heat, pressure, and chemical processes involved in the moulding process are managed to eliminate potential damage.
We have been overmoulding cables, components and connectors for many years and aim to consistently surprise our customers by breaking new ground with the technology. As well as precise overmoulding of thermoplastics we also have the equipment and experience to provide potting or other encapsulation of components in cases where these processes may be more economical or appropriate.
We are happy to talk to you about low pressure and two shot moulding processes and to help you find the technology to support your product. Using sophisticated materials such as Liquid Crystal Polymer we can work at tolerances as small as 13 microns and wall thicknesses as low as 0.3mm which is one reason why we call what we do precision technical moulding.
WHAT IS OVERMOULDING?
OVERMOULDING IS THE PROCESS OF ADDING AN ADDITIONAL LAYER OF MATERIAL TO AN EXISTING COMPONENT. THE BASE COMPONENT IS PLACED IN THE INJECTION MOULD TOOL AND PLASTIC FILLS THE CAVITY AROUND THE INSERTED PART
Overmoulding has many benefits, it reduces costs by eliminating secondary assembly operations, parts can attain a high degree of waterproofing and shock resistance, parts produced using overmoulding are tough, lightweight and chemical resistant. Various textures can be achieved, the surface can be soft touch for handling or tough for durability, products are better insulated, aesthetically pleasing and sharp edges minimised or eliminated. Many components are suitable for overmoulding including sensitive electronics and cables.
Overmoulding components with plastic improves product functionality, reliability, ergonomics, aesthetics and costs. The overmoulding process allows for greater design flexibility by incorporating features such as mounting clips and reduces the need for additional components.
Sensitive electronic components such as PCBs can be overmoulded, offering impact protection and IP rated defence from the ingress of moisture and dust where the overmoulded structure provides protection against harsh environments.
The overmoulding of cables protects and secures all cables, connectors, pins & components, provides flexible strain relief and allows for multiple cable orientation, reduced labour costs and enhances the integrity and lifespan of the product.
Overmoulding of connectors and fasteners protects them against corrosion, reduces the impact of vibration and aids the assembly process. With the wide range of colours available overmoulded connectors blend seamlessly with their application and make your product look even better.
Overmoulding is extensively used in many industrial sectors including Military, Automotive, Marine, Power Supplies, Industrial Control, Sensors and Audio and is suitable for products such as: Cable Assemblies, Electronic Components, Connectors and Pins, Fasteners.
Inoplas has taken a number of our customers through the design and specification process to produce very high quality overmouldings for numerous applications and we like nothing better than to see a customer’s eyes light up when we show them how they can reduce costs and improve function by harnessing our skills.
With 24 moulding machines offering clamp forces up to 180 tonnes and shot capacities from 0.5 to 380 grams, our 50-strong workforce can deliver all types of moulding, insert moulding and over moulded assemblies. We work on a daily basis with a very broad range of high specification engineering and developmental plastics from simple ‘commercial’ polymers to the very latest metal replacement ranges. We have developed particular skills in the manufacture of overmoulded components.
Over the years we have made tooling for thousands of new products and have produced mouldings in over 200 different grades of technical thermoplastics (many of which are kept in stock). The range of polymers we use reflects the profile, range and complexity of the projects that we are asked to undertake.
- ABS, LCP, PE, PBT, Acetal, Nylon, Polycarbonate, PPS, Acrylic, TPE, Polypropylene, PPA & many others.
In July 2014 Inoplas developed the Moover cow slipper for a customer. The slipper is designed for dairy cows, who have a problem in one of their hoof “claws”. The slipper allows the infected “claw” to be raised off the ground and heal quickly.