There are many applications that require several materials to be combined together to make a single product. One of the processes through which several materials are combined to make a single item is referred to as overmolding. This process involves a substrate material over which overmold material or materials are applied to partially or fully cover it. Once the overmold material has been applied, it forms a single item with the substrate.
There are many different examples of substrates in use including plastics, wood, ceramic, glass, and metals. Complete products such as threaded inserts, screws, molded plastic parts, machined metal parts, and electrical connectors may also be used as substrates. The final product has the substrate making the first part and an overmold component making the second part. These two are mechanically interlocked and chemically bonded into one.
Various types of overmold materials are in existence today. Rubber and plastics have however stood out as the most commonly used overmold materials. During the process, small pellets are made of the overmold substance before addition of additives like foaming agents and colorants. Careful choosing is necessary because of compatibility issues. Metals and plastics always work well together because they form a strong bond with each other.
However, plastic and rubber substrates pose compatibility issues with overmold plastics or rubber. Manufacturers of overmold materials usually publish a chart indicating what substrates the materials is compatible with and to what extent. Depending on the kind of product being made and its specific application, the compatibility chart should be studied carefully. Overmold material that produces the strongest bond and strength between the substrate and itself should be used.
Several different industries and settings have application for this process. Various products are made using this process. Some of the products include screw drivers, casters, cans, tools, toothbrushes, laptops, and handgrips. There are a few versions of this process in use, including plastic over plastic, plastic over metal, rubber over metal, and rubber over plastic.
During the procedure, part or the entire substrate is put inside an injection molding equipment. The substrate material is then applied with shots of overmold material onto, into, around it. After the shots are applied, time must be allowed for the overmold substance to cool down and solidify in a process called curing. The final product is a single, joined component.Introducing interlocking mechanisms is advised to make the bonding stronger.
There are many different reasons why people engage in this process. The first reason is to enhance the aesthetics of a product. This process helps to break up color in a product by introducing another color. The final product can have multiple colors, which make it to look better. The second reason is for introducing soft or flexible areas in a rigid part. For instance, rubber parts may be introduced to a plastic or metal handle to make handling easier.
Another important aspect of this process is reduction or elimination of assembly line time. One can avoid spending time and resources on producing various components that will later be rejoined by only making a single substrate and applying overmold materials. Additionally, application of overmold materials also prevent the use of fasteners and adhesives.
There are many different examples of substrates in use including plastics, wood, ceramic, glass, and metals. Complete products such as threaded inserts, screws, molded plastic parts, machined metal parts, and electrical connectors may also be used as substrates. The final product has the substrate making the first part and an overmold component making the second part. These two are mechanically interlocked and chemically bonded into one.
Various types of overmold materials are in existence today. Rubber and plastics have however stood out as the most commonly used overmold materials. During the process, small pellets are made of the overmold substance before addition of additives like foaming agents and colorants. Careful choosing is necessary because of compatibility issues. Metals and plastics always work well together because they form a strong bond with each other.
However, plastic and rubber substrates pose compatibility issues with overmold plastics or rubber. Manufacturers of overmold materials usually publish a chart indicating what substrates the materials is compatible with and to what extent. Depending on the kind of product being made and its specific application, the compatibility chart should be studied carefully. Overmold material that produces the strongest bond and strength between the substrate and itself should be used.
Several different industries and settings have application for this process. Various products are made using this process. Some of the products include screw drivers, casters, cans, tools, toothbrushes, laptops, and handgrips. There are a few versions of this process in use, including plastic over plastic, plastic over metal, rubber over metal, and rubber over plastic.
During the procedure, part or the entire substrate is put inside an injection molding equipment. The substrate material is then applied with shots of overmold material onto, into, around it. After the shots are applied, time must be allowed for the overmold substance to cool down and solidify in a process called curing. The final product is a single, joined component.Introducing interlocking mechanisms is advised to make the bonding stronger.
There are many different reasons why people engage in this process. The first reason is to enhance the aesthetics of a product. This process helps to break up color in a product by introducing another color. The final product can have multiple colors, which make it to look better. The second reason is for introducing soft or flexible areas in a rigid part. For instance, rubber parts may be introduced to a plastic or metal handle to make handling easier.
Another important aspect of this process is reduction or elimination of assembly line time. One can avoid spending time and resources on producing various components that will later be rejoined by only making a single substrate and applying overmold materials. Additionally, application of overmold materials also prevent the use of fasteners and adhesives.
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