Overmoulded & 2-Shot Applications
Overmoulding and 2-shot (or twin-shot) moulding are advanced manufacturing processes that allow for the production of multi-material parts in a single, highly efficient process. These techniques are commonly used in industries where complex, multi-functional components are required, such as automotive, consumer electronics, medical devices, and industrial equipment. Abbey Polymers supplies a wide range of specialised polymers and compounds that are ideally suited for overmoulding and twin-shot applications, helping manufacturers create innovative, durable, and aesthetically pleasing products.
What are Overmoulding & 2-Shot Moulding?
- Overmoulding involves moulding one material (typically a soft polymer such as TPE or TPU) over another, usually more rigid material (such as ABS, PC, or PA), to create a single integrated component. This process is often used to add ergonomic features like soft grips or to create seals and gaskets that require flexibility and precision.
- 2-Shot Moulding (or twin-shot moulding) is a similar process where two different materials are injected into the mould sequentially in a single production cycle. This technique allows for more complex designs and stronger bonds between the two materials, as the second material is injected while the first is still partially molten, creating a strong chemical and mechanical bond.
Polymers & Compounds for Overmoulding & 2-Shot Moulding
Overmoulding and twin-shot moulding require materials with excellent adhesion properties to ensure a strong bond between the different layers. The selection of polymers for these processes is critical to achieving the desired performance, durability, and appearance of the final product.
Some of the most commonly used polymers and compounds for overmoulding and 2-shot applications include:
- Thermoplastic Elastomers (TPEs): TPEs, such as those from Abbey Polymers’ partner Kraiburg TPE, are widely used in overmoulding due to their soft-touch properties, flexibility, and compatibility with a variety of rigid substrates like ABS, PC, and PA. TPEs are ideal for applications such as grips, seals, and cushioning elements that require both comfort and durability.
- Thermoplastic Polyurethanes (TPUs): TPUs offer excellent resistance to abrasion, chemicals, and wear, making them suitable for overmoulding onto rigid substrates in applications that require enhanced durability. They are commonly used in exterior automotive components, electronic casings, and industrial tools.
- Polypropylene (PP): PP is often used as a rigid substrate in overmoulding processes due to its lightweight properties and chemical resistance. It can be combined with softer materials like TPE to create products that require both structural integrity and flexibility.
- Engineering Polymers: Materials like polyamide (PA), polycarbonate (PC), and acrylonitrile butadiene styrene (ABS) are frequently used as the rigid component in overmoulded or twin-shot applications. These materials provide the necessary strength and rigidity for components that must withstand mechanical stress, while the overmoulded layer adds functionality, such as improved grip or insulation.
Features & Benefits of Overmoulded & 2-Shot Applications
- Enhanced Product Functionality: Overmoulding and twin-shot moulding allow manufacturers to create parts that combine different properties, such as rigidity and flexibility, in a single component. This enables the production of multi-functional products that offer enhanced performance and user experience.
- Improved Aesthetics: By combining different materials in a single part, overmoulding and twin-shot moulding enable the creation of products with more appealing designs, including multi-coloured or textured surfaces. This is especially important for consumer products where aesthetics and ergonomics are critical to market success.
- Durability and Strength: Overmoulding and twin-shot moulding create a strong bond between the different materials, improving the durability and longevity of the final product. This is particularly beneficial in applications where parts are subjected to repeated use, stress, or exposure to harsh conditions.
- Cost Efficiency: These processes reduce the need for secondary operations, such as assembly or glueing, resulting in lower manufacturing costs and shorter production times. By streamlining production, manufacturers can improve overall efficiency and reduce the risk of part failure due to assembly errors.
Typical Applications for Overmoulding & 2-Shot Moulding
- Automotive: Interior components, such as soft-touch dashboard panels, buttons, and seals, that combine aesthetics with functionality.
- Consumer Electronics: Smartphone cases, wearables, and other handheld devices that require both protection and a comfortable grip.
- Medical Devices: Ergonomic handles for surgical instruments, flexible seals for diagnostic equipment, and multi-material medical devices that require both rigidity and softness.
- Industrial: Tool handles, protective casings, and gaskets that need to withstand harsh environments while providing user comfort and protection.
Discover the Perfect Materials for Your Next Project
Choosing the right materials is crucial to the success of your overmoulding and 2-shot moulding projects. At Abbey Polymers, we offer a diverse range of high-performance polymers tailored to meet the unique demands of your application. Contact us today to discuss your material requirements, request samples, or explore how our expert team can help you select the best materials for your innovative designs.