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Overmolded Electronic Module Connector

Overmolded Electronic Module Connector

overmoulded on rotary tables with the joint designed for bond strength, verified by pull and peel testing on T1 samples.

Overmolded Electronic Module Connector

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Product Overview Specifications Related Custom Services

Product Overview

We produce overmoulded electronic module connectors on 320T and 800T rotary tables, so the hard substrate and the soft or second material are moulded in one cycle and the bond is formed in the tool rather than by a later gluing step.

The bond is the whole point of this process, so we design the joint, not just the part: mechanical interlock through holes and undercuts, substrate pre-treatment where the material pair needs it, and a gate and vent layout that does not trap gas at the bond line.

Material combinations

  • TPE and TPU onto ABS, PC, PC/ABS, PA and PBT
  • Two-shot rigid combinations such as PC/ABS with PMMA or ASA
  • Metal inserts, terminals and stamped components overmoulded in place
  • Silicone LSR where a higher temperature or medical grade is required

Joint design

  • Mechanical interlock by through-holes, dovetails and undercuts
  • Substrate pre-treatment and drying where the pair requires it
  • Gate position and venting set to keep the bond line free of gas traps
  • Pull and peel testing on the T1 samples to confirm the bond holds

Material is selected to your drawing. The grades listed are the ones we run most often for this type of part; we confirm the choice at DFM rather than assuming it.

Specifications

ParameterValue
Processinsert overmolding of connectors and contacts
Equipment320T and 800T rotary tables for two-shot and insert work
Soft materialTPE, TPU and silicone LSR, 30–90 Shore A
SubstrateABS, PC, PC/ABS, PA, PBT, PMMA and metal inserts
Bond verificationPull and peel testing on T1 samples, reported per batch
Shrinkage compensationSoft and rigid materials sized on their own shrinkage; mold tolerance set at 50% of product tolerance
Tool life200,000–500,000 shots on pre-hardened steel, 500,000–1,000,000 shots on hardened inserts
Lead timeTool 4–6 weeks, T0 in 3–5 days, T1 in 5–7 days
CertificationISO 9001:2015, IATF 16949:2016, ISO 13485:2016, AS9100 Rev D

Related Custom Services

  • Single-material injection molding of either component on its own
  • Insert molding of stamped terminals, bushings and threaded inserts
  • Heat staking and ultrasonic welding of the finished assembly
  • DFM review of the joint geometry before the tool is cut

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Product Overview

Product Overview

We produce overmoulded electronic module connectors on 320T and 800T rotary tables, so the hard substrate and the soft or second material are moulded in one cycle and the bond is formed in the tool rather than by a later gluing step.

The bond is the whole point of this process, so we design the joint, not just the part: mechanical interlock through holes and undercuts, substrate pre-treatment where the material pair needs it, and a gate and vent layout that does not trap gas at the bond line.

Material combinations

  • TPE and TPU onto ABS, PC, PC/ABS, PA and PBT
  • Two-shot rigid combinations such as PC/ABS with PMMA or ASA
  • Metal inserts, terminals and stamped components overmoulded in place
  • Silicone LSR where a higher temperature or medical grade is required

Joint design

  • Mechanical interlock by through-holes, dovetails and undercuts
  • Substrate pre-treatment and drying where the pair requires it
  • Gate position and venting set to keep the bond line free of gas traps
  • Pull and peel testing on the T1 samples to confirm the bond holds

Material is selected to your drawing. The grades listed are the ones we run most often for this type of part; we confirm the choice at DFM rather than assuming it.

Specifications

Specifications

ParameterValue
Processinsert overmolding of connectors and contacts
Equipment320T and 800T rotary tables for two-shot and insert work
Soft materialTPE, TPU and silicone LSR, 30–90 Shore A
SubstrateABS, PC, PC/ABS, PA, PBT, PMMA and metal inserts
Bond verificationPull and peel testing on T1 samples, reported per batch
Shrinkage compensationSoft and rigid materials sized on their own shrinkage; mold tolerance set at 50% of product tolerance
Tool life200,000–500,000 shots on pre-hardened steel, 500,000–1,000,000 shots on hardened inserts
Lead timeTool 4–6 weeks, T0 in 3–5 days, T1 in 5–7 days
CertificationISO 9001:2015, IATF 16949:2016, ISO 13485:2016, AS9100 Rev D
Related Custom Services

Related Custom Services

  • Single-material injection molding of either component on its own
  • Insert molding of stamped terminals, bushings and threaded inserts
  • Heat staking and ultrasonic welding of the finished assembly
  • DFM review of the joint geometry before the tool is cut
Overmolded Electronic Module Connector
overmoulded on rotary tables with the joint designed for bond strength, verified by pull and peel testing on T1 samples.
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