Over molding & Insert Molding
Precision-Engineered Multi-Material Components: Advanced Over molding & Insert Molding Solutions
“Seamless Material Integration in a Single Automated Cycle”
5/5
Years of experience
Precision Multi-Material Manufacturing: Over molding & insert Molding Techniques
Over molding and insert molding represent the pinnacle of multi-material manufacturing, enabling seamless integration of dissimilar substrates (plastics, metals, elastomers) with micron-level accuracy. These advanced processes deliver unmatched structural integrity by creating molecular-level bonds between materials – eliminating adhesives, fasteners, and secondary assembly while maintaining tolerances as tight as ±0.005mm (validated per ASTM D6862).
Precision Engineering Breakdown
1. Material Science Perfected
Thermoplastic-Elastomer Fusion: Chemically bonded TPE-to-PP/ABS interfaces with >95% adhesion strength (ISO 813)
Metal-Plastic Hybrids: Encapsulated stainless steel/brass inserts withstand 50+ kN pull-out forces (DIN 14889)
2. Process Control at Microscopic Scales
Mold Alignment: <5μm cavity-to-cavity variation for multi-shot systems (validated via CT metrology)
Thermal Management: ±1°C zone-controlled heating prevents stress concentrations at material junctions
3. Industry-Proven Applications
Medical: USP Class VI compliant handles with antimicrobial TPE over PEEK cores
Automotive: Vibration-damped sensor housings (aluminum inserts molded with PPA)
Electronics: EMI-shielded connectors (overmolded conductive plastics on brass terminals)
20,000+ Precision Parts, 150+ Materials
4.9/5
Tolerance Standard
±0.0005" Precision Guarantee
Since 2015
5/5
Surface Finish
C8-16 μin Ra Mirror Finish
Since 2015
4.8/5
Maximum Workpiece
40" × 28" × 20" Capacity
Since 2015
4.5/5
Material Hardness
Up to 65 HRC Processed
Since 2015
Tolerance for Molding Services
Limits for nominal size
Metals (ISO 2768- f)
Plastics (ISO 2768- m)
0.5mm* to 3mm
±0.05mm
±0.1mm
Over 3mm to 6mm
±0.05mm
±0.1mm
Over 6mm to 30mm
±0.1mm
±0.2mm
Over 30mm to 120mm
±0.15mm
±0.3mm
Over 120mm to 400mm
±0.2mm
±0.5mm
Over 400mm to 1000mm
±0.4mm
±0.8mm
Over 1000mm to 2000mm
±0.5mm
±1.2mm
Molding Performance Specifications
| Category | Parameter | Standard Grade | Precision/Medical Grade | Validation Method |
|---|---|---|---|---|
| Material Bonding | ||||
| Adhesion Strength | 3-5 MPa (Mechanical) | 8-12 MPa (Chemical) | ASTM D6862 | |
| Peel Resistance | 20-40 N/cm | 50-80 N/cm | ISO 813 | |
| Dual-Material Properties | ||||
| Hardness Differential | ≤30 Shore A | ≤15 Shore A | ASTM D2240 | |
| CTE Mismatch Tolerance | Δ5 ppm/°C | Δ2 ppm/°C | ASTM E831 | |
| Process Capabilities | ||||
| Insert Positioning Acc. | ±0.010″ | ±0.002″ | Vision System (5μm) | |
| Overmold Thickness | 0.5-3.0 mm | 0.2-1.5 mm | Micro-CT Scan | |
| Performance Testing | ||||
| Thermal Cycling | -40°C to +85°C (500 cycles) | -60°C to +150°C (1000 cycles) | IEC 60068 | |
| Chemical Resistance | IPA, Mild Detergents | Sterilants, Oils | ISO 1817 | |
| Medical Compliance | ||||
| Biocompatibility | – | USP Class VI, ISO 10993 | Extractables Testing | |
| Sterilization | 50 cycles (EtO) | 300 cycles (Gamma) | AAMI ST108 |
Materials we provides for molding
Tool Steel (high wear resistance)
D3 is a high carbon, high chromium tool steel known for its excellent wear resistance and ability to maintain a sharp edge. It is commonly used for cutting tools, dies, and industrial applications requiring high durability.
Subtypes:
- D3 (Standard)
- D3 Cold Work Tool Steel
Pre-Hardened Tool Steel
P21 is a pre-hardened tool steel that offers good machinability and wear resistance. It is ideal for making molds and dies, as it doesn’t require extensive heat treatment.
Subtypes:
- P21 (Standard)
- P21+ (Improved)
Hot Work Tool Steel
H11 is a hot work tool steel known for its toughness and thermal fatigue resistance. It is used in applications involving high temperatures, such as die casting and forging.
Subtypes:
- H11 (Standard)
- H11A (Modified for improved toughness)
Polyoxymethylene (Acetal)
POM is a high-performance engineering thermoplastic known for its low friction, high stiffness, and excellent dimensional stability. It’s widely used in precision parts and mechanical components.
Subtypes:
- POM-C (Copolymer)
- POM-H (Homopolymer)
Polyamide (Nylon)
PA is a versatile synthetic polymer known for its high strength, toughness, and excellent chemical and wear resistance, commonly used in textiles, automotive components, and industrial applications.
Subtypes:
- PA(Nylon) Blue
- PA6 (Nylon)+GF15 Black
- PA6 (Nylon)+GF30 Black
- PA66 (Nylon) Beige (Natural)
- PA66 (Nylon) Black
Polypropylene
PP is a lightweight, durable thermoplastic known for its chemical resistance and versatility. It is widely used in packaging, automotive parts, and consumer goods.
Subtypes:
- PP Homopolymer
- PP Copolymer
High-Density Polyethylene
HDPE is a strong and versatile thermoplastic known for its high strength-to-density ratio. It is commonly used in containers, piping, and plastic bottles.
Subtypes:
- HDPE (Standard)
- HDPE (Recycled)
Low-Density Polyethylene
LDPE is a flexible and durable thermoplastic known for its low density and high chemical resistance. It is often used in packaging films and bags.
Subtypes:
- LDPE (Standard)
- LDPE (Recycled)
Polycarbonate
PC is a strong, impact-resistant thermoplastic known for its clarity and heat resistance. It is commonly used in eyewear lenses, safety equipment, and electronic components.
Subtypes:
- PC (Standard)
- PC (Flame Retardant)
High-Impact Polystyrene
HIPS is a tough and impact-resistant thermoplastic known for its ease of processing and good surface finish. It is commonly used in consumer products and packaging.
Subtypes:
- HIPS (Standard)
- HIPS (Recycled)
Polybutylene Terephthalate
PBT is a thermoplastic engineering polymer known for its excellent mechanical properties and chemical resistance. It is often used in automotive and electrical applications.
Subtypes:
- PBT (Standard)
- PBT (Reinforced)
Polyamide-imide
PAI is a high-performance thermoplastic known for its excellent thermal stability and mechanical properties. It is used in high-temperature applications and aerospace components.
Subtypes:
- PAI (Standard)
- PAI (Filled)
High-Speed Steel
M2 is a high-speed steel known for its high hardness, wear resistance, and ability to retain hardness at elevated temperatures. It is commonly used for cutting tools and drills.
Subtypes:
- M2 (Standard)
- M2 (Coated)
High-Speed Steel
HSS is a high-performance tool steel known for its ability to cut at high speeds without losing hardness. It is widely used in manufacturing cutting tools.
Subtypes:
- HSS (Standard)
- HSS (Coated)
Polyether Ether Ketone
PEEK is a high-performance thermoplastic known for its excellent chemical resistance and thermal stability. It is used in specialized applications such as aerospace and medical devices.
Subtypes:
- PEEK (Standard)
- PEEK (Reinforced)
Polymethyl Methacrylate
PMMA is a transparent thermoplastic known for its clarity and UV resistance. It is commonly used as a lightweight alternative to glass in various applications.
Subtypes:
- PMMA (Standard)
- PMMA (Impact Resistant)
Polytetrafluoroethylene (Teflon)
PTFE is a high-performance fluoropolymer known for its non-stick properties and chemical resistance. It is widely used in coatings, seals, and gaskets.
Subtypes:
- PTFE (Standard)
- PTFE (Filled)
Molding Surface Finishes
We provide finishes for aesthetics and performance: anodizing, polishing, sandblasting, coatings, and heat treatment. Let’s find the right one!
As Machined
This machined finish is rough and displays tool marks, representing the most basic form of surface treatment without any additional finishing or polishing.
Anodizing
It creates a protective oxide layer on aluminum, increasing corrosion resistance and hardness, and allowing for dyeing to enhance appearance.
Polishing
Polishing smooths surfaces to a high sheen, enhancing appearance and reducing roughness while offering some corrosion protection.
Brushed Finish
A brushed finish has fine, parallel lines for a textured look, enhancing grip and reducing fingerprints.
Sandblasting
Sandblasting uses high-pressure air and abrasive particles to clean or texture surfaces, enhancing adhesion for coatings.
Electropolish
Electropolishing is an electrochemical process that smooths and brightens metal surfaces, removing imperfections and enhancing corrosion resistance.
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