Overmoulding is the process of adding an additional polymer layer over an already existing component or part – and is the best option when:
- two-shot is not a feasible option
- a part may require material feeding in a complex format to both core and cavity regions
- an existing component needs adapting or enhancing
- a component derives from a separate manufacturer or process
It may be the appropriate choice when adding certain characteristics to a component or product – for example, by adding texture, surface resistance, colour variation, or perhaps impact resistance and shock absorption.
The original component is placed in the mould tool, and the new polymer injected. It is important in this process that the new polymer is compatible with the original component, which would typically be a rigid plastic. It is also feasible to consider using elastomeric compounds as the substrate, however this process carries a little more risk and therefore warrants far more planning.
Overmoulding can be more labour intensive than two-shot moulding, and hence more costly, yet can also offer a labour saving compared a similar manual process. These pro’s and con’s need to be evaluated on a case by case basis.
A high level of technical expertise and attention to detail is needed to achieve your goals, and would normally require our involvement at an early stage in the design process.