After working through the above two steps (understanding your part function and optimizing your part design for manufacturing), you should have a solid set of parameters for material selection. The challenge with material selection is that there are literally thousands of overmolding materials to choose from, and new ones are developed practically every week. That’s why when we are evaluating a new overmolding project, we go straight to our suppliers and make sure we have the best materials for the job.
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Most plastics manufacturers have application engineers to evaluate each application and stay in touch with the latest developments. There is no reason not to leverage their experience and knowledge. At the same time, we want to understand some general factors in material selection, like adhesion. We also want to have a solid grasp of material properties, like hardness and friction.
When selecting material, both the substrate and the overmold material should be considered. TPE plastic comes in several variations based on physical properties like elasticity and hardness, as well as its ability to adhere to other plastics. For example, one TPE could “feel” the same as another but may not adhere well to a polypropylene substrate. Here are some factors to consider:
We’ll also discuss how Low-pressure molding simplifies the process of creating robust, moisture-resistant, and durable enclosures for sensitive components, making it an invaluable tool in today’s manufacturing landscape.
Low-pressure molding is a manufacturing technique for sealing and protecting sensitive electronics and sensitive components. It’s used in various industries to create a snug, protective layer around these mold parts.
The basic idea is to melt special, low-temperature plastic materials and gently mold them around the component. Low-pressure molding is unique because it doesn’t involve high temperatures or pressures, which can harm delicate electronics. Instead, it operates at low pressures and temperatures.
The process is quick and efficient, ensuring the encapsulated components in the plastics industry are safe from moisture, dust, and other environmental factors. Low-pressure molding is especially valuable when sealing intricate shapes and small spaces. This technology simplifies manufacturing time and is essential in today’s production world.
Low-pressure molding is a streamlined way of creating protective coverings for several components. Unlike the traditional potting process, which involves a more complex seven or eight-step process, the Low-Pressure Molding process requires only three simple steps.
Initiating the process involves heating adhesive thermoplastic polyamide materials, often called “hot melts.” These materials, derived from natural fatty acids, prevent harmful emissions. They are heated in a sizeable hopper, preparing for the molding phase.
The low-pressure molding process in the Polyamides market exhibits robust growth, with a CAGR of -0.4%, currently valued at USD 572.6 million globally and projected to reach USD 557.4 million by 2027.
Now, the component to be protected, like wires or electrical parts, is placed into one half of the mold. The other half of the mold is closed, creating a space around the mold components. An injection molding machine gently pumps the liquified thermoplastic into the mold cavity until it’s filled.
Although the low-pressure injection molding process is slower than the high-pressure compression molding process, it’s still pretty quick, usually taking around 30 seconds, depending on the part’s size.
After injecting the molding material, the mold set is opened to allow the over-molded part to cool. Here’s where Low-Pressure Molding shines. Unlike the traditional potting process, which needs a lengthy curing, Low-Pressure Molding cools rapidly at room temperature. That means you can remove the molded part from the mold and test it shortly after the injection.
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Low-pressure molding is a revolutionary manufacturing technique that brings many advantages. Let’s delve into these key benefits in more detail, highlighting how this technology simplifies production and enhances the quality of end products.
One of the most compelling aspects of Low-Pressure Molding is its simplicity and efficiency. The process is designed to be straightforward, making it easy to understand and execute. This user-friendly approach means quicker mass production without compromising on quality. You don’t need to be a manufacturing expert to appreciate the streamlined nature of this method.
Low-pressure molding process isn’t just a set of manufacturing steps or techniques; it’s a lightning-fast process. The process ensures that your products are ready in no time. It excels in efficiency, easily adapting to various component sizes and shapes. Low-pressure molding can handle everything, whether dealing with intricate or large components. This flexibility is a significant asset in a world where customization is increasingly important.
One standout feature of Low-Pressure Molding is its environmental friendliness. During the molding process, no harmful gases are generated. Moreover, the various materials used are derived from natural sources, which is a win for sustainability. This means you can easily recycle excess materials and scraps, minimizing waste and environmental footprint.
Low-pressure molding is not only efficient but also budget-friendly. It requires fewer resources and less energy than traditional methods, making it a cost-effective choice. The best part is that you don’t need expensive molds – even aluminum molds work exceptionally well while maintaining durability. This reduces your overhead costs significantly.
Low-pressure molding empowers you to customize your products to meet specific needs. It’s adaptable, ensuring a perfect fit every time. This customization ability is invaluable in a world where consumers and industries demand tailored solutions.
The final products are incredibly lightweight, making them easy to handle and transfer molding. They’re also waterproof, heat-resistant, and capable of withstanding harsh conditions, including shock and external factors. This resilience ensures that your products remain reliable even in demanding environments.
Beyond functionality, Low-Pressure Molding enhances the overall appearance of your products. Its flexibility means there’s no need for additional insulation, resulting in sleek and polished final products. This aesthetic improvement can set your products apart in a competitive market.
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Low-pressure molding finds a wide range of applications across various industries thanks to its unique qualities and advantages compared to other molding techniques. Let’s explore some of the key areas where Low-Pressure Molding excels.
In electronics, Low-Pressure Molding is a game-changer. It’s used to protect delicate components and wiring from harsh environments. This includes safeguarding:
Low-pressure molding is the linchpin that offers a protective layer that is not just waterproof but also shock-resistant and reliable, ensuring the longevity of electronic devices in challenging conditions.
The automotive industry relies on Low-Pressure Molding for sealing and safeguarding sensitive electronic components. It is extensively applied to protect:
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Low-pressure molding technology guarantees that these components can endure the rigorous demands of the automotive sector, where temperature fluctuations and vibrations are commonplace.
In the medical field, Low-Pressure Molding is used to encapsulate and protect electronics within medical devices, such as:
This application is paramount in guaranteeing the reliability and safety of these life-saving devices, where precision and consistency are of utmost importance.
The aerospace industry relies on Low-Pressure Molding to protect electronic components used in aircraft. This technology is applied to secure:
With the ability to withstand high temperatures and challenging conditions, Low-Pressure Molding ensures the integrity of these components in the aerospace environment.
Low-pressure molding extends to the consumer goods sector, which creates products with enhanced durability and functionality. This includes:
The technology protects these devices and enhances their aesthetic appeal, making them more appealing to consumers.
In the industrial sector, Low-Pressure Molding is employed to safeguard and enhance the performance of various equipment, including:
This application is critical to ensure the reliability and longevity of industrial equipment, where downtime can be costly.
In the renewable energy sector, Low-Pressure Molding plays a crucial role in protecting electronic components used in:
Low-pressure molding is instrumental in contributing to the reliability of renewable energy systems, where the robustness of electronic components is paramount for consistent energy production.
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Two predominant techniques have emerged in injection molding: Low-Pressure Molding and High-Pressure Injection Molding. Each of these methods offers distinct advantages and is suited to different applications. Let’s compare and contrast the two to understand their key differences and when to employ them.
FeatureLow-Pressure MoldingHigh-Pressure MoldingPressure AppliedTypically up to 100 psiThousands to 20,000 psi or moreMaterials UsedThermosets, polyamidesThermoplastics, some thermosetsTooling CostGenerally lowerHigherCycle TimeUsually longerShorterMold WearReduced due to lower pressureFaster due to higher pressurePart ComplexitySuitable for less complex partsCan handle more complex geometriesPart QualityGood for encapsulating partsOften higher precision and finishPart StrengthGenerally adequateTypically strongerWasteLess waste due to overflowsCan have more waste due to sprue and runnersSetup TimeOften quickerCan be longer due to precise controlsApplicationsElectronics encapsulation, gasketsAutomotive parts, consumer goods, medical devicesEquipment CostGenerally lowerHigher due to advanced machineryMaterial EfficiencyCan be more efficient for certain applicationsOften maximizes material usage, but with some wasteLow-pressure molding is environmentally friendly as it limits harmful gas emissions. Besides, it consumes natural resources and recycles waste thus minimizing our carbon footprint. Apart from that, it ensures maximum efficiency and flexibility as it handles all sizes and shapes of components without compromising on quality.
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Low-pressure molding offers a wide array of custom material options, allowing manufacturers to tailor the protective covering precisely to the needs of their components and applications. This flexibility is a key advantage of Low-Pressure Molding, as it ensures that the final product meets the specific requirements of each project.
Here’s a closer look at the custom material options available in Low-Pressure Molding:
Due to its unique benefits, low-pressure molding is an attractive choice for various applications. Here’s why you should consider it for your specific needs:
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Low-pressure molding is a revolutionary manufacturing method that offers protection, customization, efficiency, eco-friendliness, and cost-effectiveness. It is used in various industries like electronics, automotive, medical devices, aerospace, consumer goods, industrial equipment, and renewable energy.
It provides a reliable solution for safeguarding delicate components and enhancing product performance through injection molding plastics. Its advantages include speed, eco-friendliness, cost-efficiency, and versatility.
If you’re ready to explore the possibilities and harness the benefits of Low-Pressure Molding for your unique needs, we invite you to take the next step. Contact Hongju‘s experts today to discuss how this innovative technology can transform your manufacturing process and elevate the quality of your products.
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