At BHC Associates, our Injection molding group understands the challenges faced by electronic and medical device manufacturers. With the vast combined experience of our experts, we bring their diverse knowledge of various molding processes to your projects. If you are looking to incorporate low pressure overmolding into your manufacturing operations read on to learn how this molding process can benefit you.
Delicate electrical components or otherwise sophisticated items such as medical devices often require an extra layer of protection in order to ensure reliable functionality and durability. This is where low pressure overmolding can provide a simple yet effective solution. Low pressure overmolding is essentially an encapsulation or overmolding method that covers sensitive components, parts, or items in a protective thermoplastic shell. This is generally done through a reactive injection molding process. The method is highly effective in protecting sensitive electronics from a variety of damaging elements such as moisture, dirt, air, heat ,and vibration. Low pressure overmolding is the most optimal encapsulation solution for delicate electrical devices because of its low pressure and heat requirements when compared to other methods. In addition various plastic parts or products of varying designs and sizes can be produced via low pressure overmoulding such as medical device parts or other items.
Enhanced protection and durability are only a few benefits provided by low pressure overmolding. The process also provides various other functional and aesthetic benefits. Such benefits include:
Theft/Tampering Prevention: The materials used for the overmolding of a particular item are highly durable and once the item is encapsulated tampering and IP theft become much more difficult. The part would need to be broken in order to be tampered with or removed.
Streamlined Manufacturing: Generally, low pressure overmolding requires only 3 steps to accomplish. Simply insert the item. Overmold it. And take it out. Other encapsulation methods require many more steps and don't offer the same protection. Low pressure overmolding can provide various protection features of other methods such as potting or conformal coating in one simple process. Overall cycle times are greatly reduced when using low pressure overmolding compared to other methods.
Enhanced Aesthetics / Design Flexibility: The process offers increased design and material flexibility when compared to other processes. In addition, parts and components can be encapsulated in one single piece, thereby avoiding unattractive seams, ridges, or cracks that would appear as a result of bonding or adhesives.
Enhanced Wireless Signals: The low density high performance materials that are used during the process would allow for enhanced radio or wireless signals when compared to other methods such as potting. Moreover, Antennas can be easily molded onto a device using low pressure overmolding.
Delicate electrical components or otherwise sophisticated items such as medical devices often require an extra layer of protection in order to ensure reliable functionality and durability. This is where low pressure overmolding can provide a simple yet effective solution. Low pressure overmolding is essentially an encapsulation or overmolding method that covers sensitive components, parts, or items in a protective thermoplastic shell. This is generally done through a reactive injection molding process. The method is highly effective in protecting sensitive electronics from a variety of damaging elements such as moisture, dirt, air, heat ,and vibration. Low pressure overmolding is the most optimal encapsulation solution for delicate electrical devices because of its low pressure and heat requirements when compared to other methods. In addition various plastic parts or products of varying designs and sizes can be produced via low pressure overmoulding such as medical device parts or other items.
Enhanced protection and durability are only a few benefits provided by low pressure overmolding. The process also provides various other functional and aesthetic benefits. Such benefits include:
Theft/Tampering Prevention: The materials used for the overmolding of a particular item are highly durable and once the item is encapsulated tampering and IP theft become much more difficult. The part would need to be broken in order to be tampered with or removed.
Streamlined Manufacturing: Generally, low pressure overmolding requires only 3 steps to accomplish. Simply insert the item. Overmold it. And take it out. Other encapsulation methods require many more steps and don't offer the same protection. Low pressure overmolding can provide various protection features of other methods such as potting or conformal coating in one simple process. Overall cycle times are greatly reduced when using low pressure overmolding compared to other methods.
Enhanced Aesthetics / Design Flexibility: The process offers increased design and material flexibility when compared to other processes. In addition, parts and components can be encapsulated in one single piece, thereby avoiding unattractive seams, ridges, or cracks that would appear as a result of bonding or adhesives.
Enhanced Wireless Signals: The low density high performance materials that are used during the process would allow for enhanced radio or wireless signals when compared to other methods such as potting. Moreover, Antennas can be easily molded onto a device using low pressure overmolding.
Low pressure Overmolding for Electronics
As mentioned, low pressure overmolding is the perfect solution when looking to add an extra layer of protection to your electronic components. The process is very flexible and allows you to overmold the most complex of electronics. Electronic items that can be encapsulated using low pressure overmolding include:
- Circuit Boards
- PCBs
- Batteries
- Connectors
- Sensors
- Switches
- Antennas
- Magnets
- Threaded Inserts
- Metal Bolts, Rods, Clips
Low Pressure Overmolding for Medical Devices
In the medical field it is important that devices remain in top condition.Benefits mentioned above such as enhanced durability, theft/ tampering prevention, enhanced aesthetics, streamlined manufacturing, and wireless support all apply to medical devices however there are a few other details that are worth mentioning.
Sanitation: in terms of design, overmolded parts will have less ridges, cracks, and seams. These imperfections can often collect dirt, bacteria, and germs.
Streamlined Operations/ Lower Costs: Medical devices are generally produced at low volumes. Low pressure overmolding is a streamlined and flexible process that can produce parts for medical devices of all sizes and designs making it the perfect process to manufacture expensive low volume medical device parts. Additionally, given that low pressure overmolding is a reactive injection molding method the tooling cost is also reduced in some cases.
Aesthetics: It is important for medical devices to put forth a positive image of dependability and sophistication. Low pressure overmolding has the ability to make medical devices look as refined on the outside as they are on the inside and vice versa.
Sanitation: in terms of design, overmolded parts will have less ridges, cracks, and seams. These imperfections can often collect dirt, bacteria, and germs.
Streamlined Operations/ Lower Costs: Medical devices are generally produced at low volumes. Low pressure overmolding is a streamlined and flexible process that can produce parts for medical devices of all sizes and designs making it the perfect process to manufacture expensive low volume medical device parts. Additionally, given that low pressure overmolding is a reactive injection molding method the tooling cost is also reduced in some cases.
Aesthetics: It is important for medical devices to put forth a positive image of dependability and sophistication. Low pressure overmolding has the ability to make medical devices look as refined on the outside as they are on the inside and vice versa.
Low pressure overmolding systems and equipment
There are several low pressure molding systems that can be used to overmold items or produce overmolded parts. Additionally, the equipment requirements may differ depending on the application. But generally speaking low pressure molding systems are unique in that they are able to overmold components at low pressures, requiring pressures of about 100 PSI and clamping pressure of usually only 1-10 tons. Low pressure overmolding systems also have lower heat requirements and only require temperatures of 180-220℃. The materials used for a low pressure molding system will need to be of lower viscosity as well, about 2000 - 10000 mPas (cP) , a similar viscosity to pancake syrup. Aside from these general requirements low pressure overmolding systems can vary greatly depending on the application, production volume, and other factors.
There are several different low pressure overmolding systems and equipment options available in the market from handheld overmolding systems to more advanced automated molding systems. Equipment differences on low pressure molding systems may have to do with different shuttle table configurations, melt chamber options, material capacities, clamp forces , mold cavities, pump configurations, tooling options ,or a variety of other things.
There are several different low pressure overmolding systems and equipment options available in the market from handheld overmolding systems to more advanced automated molding systems. Equipment differences on low pressure molding systems may have to do with different shuttle table configurations, melt chamber options, material capacities, clamp forces , mold cavities, pump configurations, tooling options ,or a variety of other things.
What We Offer
As you can imagine, starting an overmolding project is a very complex endeavor. Work with experts you can trust. Our team of top industry experts have decades of experience in the molding industry. Each of our professionals brings diverse knowledge and expertise that you won't find anywhere else.
Let us help you start your overmolding project!
Our experts are able to assist you with:
This is only a short list of our capabilities.Rest assured our experts can provide solutions for all of your needs. If you are looking to start an overmolding project Contact our experts today!
Let us help you start your overmolding project!
Our experts are able to assist you with:
- Material recommendations and Sourcing
- Equipment and Systems Recommendations and Sourcing
- Tooling recommendations
- Operations set up
- Systems configuration
- Equipment configuration
- Mold Flow Analysis
- Part and product testing
- And much more
This is only a short list of our capabilities.Rest assured our experts can provide solutions for all of your needs. If you are looking to start an overmolding project Contact our experts today!
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