Precision overmoulding
Overmoulding is the intricate process of moulding multiple materials into one cohesive product. This is the process of choice for adding needed characteristics to a product. In overmoulding, TPE – Thermoplastic Elastomer, is bonded to harder plastics like ABS. This process offers many benefits in safety, ergonomics, functionality, and aesthetics. The process is complex and delicate, but PMP’s experts are well-versed in the process, making PMP the market leader for the overmoulding process.
A common example of overmoulding would be a toothbrush with a stiff, pre-moulded frame and rubberised grips on the handle. In the process, the base layer is moulded first and then the additional soft plastic is moulded over and around the original pre-moulded part, bonding the two. The result is an incredibly strong mechanical bond.
It’s all in the detail
Overmoulding has become the manufacturing method of choice for complex components requiring multiple layers of plastic material. PMP has many years of experience with the overmoulding process, and can deliver overmoulding to an incredibly high standard, meeting ISO 9001 requirements.
Scientific principles meet with unrivalled expertise to deliver a market leading overmoulding solution. Our facilities have plastic injection moulding machines capable of producing specialist overmoulded products ranging from hand-operated Manumoulds, up to 200-ton injection moulding machines.
Limitless options with overmoulding
Overmoulding is becoming the go-to process for many manufacturers in need of complex, multilayer products. There are a range of reasons why overmoulding is preferred:
Cosmetic
Overmoulding for cosmetic purposes allow you to introduce an additional colour or a different texture to the product, changing aesthetics.
Mechanical
For mechanical usage, overmoulding is used to create a strong seal, for ongoing durability in harsh environments or industrial applications.
Insulation
The process can also be used for the electrical insulation of a cable or IP rated housing, with a watertight seal.
Cost-effectiveness
Overmoulding allows a strong bond to be created between materials without the need to introduce additional materials or labour.
Next level product moulding
The Overmoulding process offers a wide range of improvements in product resilience and appearance. One of the key benefits is reduced vibrations during product use, ideal for industrial application. Further to this, parts can be made water resistant and/or sound absorbent, depending on the use. Other benefits including product comfort and grip, improved performance and of course, improved aesthetics.
The overmoulding process is always advancing and changing. With PMP’s commitment to continuous improvement, we are quick to incorporate these changes into our manufacturing techniques, ensuring that we stay on the cutting edge of plastic tech and create exceptional products at the most cost-effective prices. All of our overmoulding production is delivered in line with ISO 9001 quality standards.
If required, our partner company, Photofabrication, can assist with the creation of intricately shaped metal components. This means you get a complete service from PMP – whatever your project, PMP can bring it to reality – and without compromise your design vision!
Tooling up a better service
Hard tooling can be an expensive investment, so maintenance and care is critical to cost efficiency and longevity. Our dedicated engineering department has the capability of creating new tooling as well as maintaining existing hard tooling to ensure tolerances and quality are maintained for as long as possible.
Overmoulding FAQs
What is overmoulding?
Overmoulding is a process where two or more materials are moulded together. Typically, a softer material like rubber is moulded over a rigid plastic part, creating enhanced grip, durability, or aesthetic appeal. Overmoulding is often used for tool handles, grips, and electrical connectors.
What are the materials that you can work with?
High-density polyethylene (HDPE)
Low-density polyethylene (LDPE)
Polypropylene (PP)
Polyethylene (PE)
Polyoxymethylene (POM, a.k.a. acetal)
Polyamide (PA, a.k.a. nylon)
Polybutylene terephthalate (PBT)
Polyethylene terephthalate (PET)
Polyphenylene sulfide (PPS)
Acrylonitrile butadiene styrene (ABS)
Polystyrene (PS)
Polycarbonate (PC)
Polyurethane (PUR or PU)
Polyetherimide (PEI, a.k.a. Ultem®)
Polysulfone (PSU)
PEEK (polyetheretherketone)
What are the benefits of a vertical injection moulding machine?
Vertical injection moulding machines provide greater flexibility for placing inserts, improved precision, and easier loading of components. They also save floor space since they typically have a smaller footprint. Additionally, vertical machines enable better part alignment, which is critical for overmoulding processes, and are ideal for applications where gravity assists in keeping inserts in place during moulding.
Download or read our latest case studies
Dunkermotoren
March 2023This leading manufacturer of drive technology required support with tooling design.
PMP Delivers Excellence to Speakerbus Technology.
March 2023PMP worked closely with Speakerbus to research new options in the form of materials, colouring, and printing solutions to find a combination that delivered the most consistent results.
Handy Dryers
March 2023Handy Dryers approached PMP for support with the challenge of having a metal front casing modelled for polished stainless steel manufacture.
Why so many businesses choose PMP
PMP specialise in high quality technical components, which we deliver to customers in numerous sectors. PMP maintains impressive customer retention thanks its commitment in providing industry leading customer service. PMP employs a commitment to quality and service that runs throughout the entire business and every stage of production. We firmly believe that outstanding service is the key to a long and successful customer relationship.
Mould your next project with PMP
If you are looking to find a complete service partner for injection moulding, get in touch today and see how we can benefit your business. Call PMP on 01371 876681 or contact us to see how PMP can bring your designs to life and handle your next manufacturing project. Keep up to date with the latest developments on LinkedIn.
Start your overmoulding journey today
Want to find out more on overmoulding and see if this is a better manufacturing process for your products? Get in touch with us and we’ll advise and take care of everything for you. Call Paul Austin on 07908 898496 or contact us now to see how PMP can bring your designs to life and handle your manufacturing project. Keep up to date with the latest developments on LinkedIn.
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