From the basics of plastic through to safety and fumes, get started on your recycling journey with online and downloadable resources.

Silicone over plastic. Adding a silicone layer to a plastic material such as PC for water resistance, sealing, and enhanced tactile properties.

Features:• Spring-loaded, height-adjustable barrel for seamless adjustments and precision crafting• Rack and pinion mechanism ensures optimised pressure for powerful leverage and professional results• Gears seamlessly convert rotation into linear motion for efficient operation• Boltable design guarantees a stable foundation for reliable injection moulding• Easy-to-mount, relocatable electrical box provides flexible setup• Premium quality stainless steel hopper designed to withstand the test of time

Complex design and engineering. Overmolding requires careful design considerations and engineering expertise to ensure proper material compatibility, bonding, and mold design, which can increase development time and costs.

As a small business looking to scale, the idea of manufacturing your own parts from recycled plastic is exciting. However, even through the material is free, the time to prepare and change over moulds can make it a costly exercise. Until now! What we love so much about this machine is the genius clamping & injection system. Ultimately this minimises mould changeover time and brings the cost to produce to a scaleable amount. Very stoked and even more excited to see what other businesses can do with this technology.

Ergonomic design. Overmolding enables the creation of ergonomic shapes and contours, enhancing user comfort and interaction, making products more user-friendly and intuitive to use.

Here you'll find everything you need to get started, from risk assessment templates to comprehensive troubleshooting guides.

Durability and protection. Overmolding can add a protective layer, such as a rubber coating, to shield delicate components from impact, moisture, or environmental factors, extending product lifespan.

Overmolding improves grip, durability, aesthetics, and reduces assembly steps, creating versatile and comfortable products.

Dive into the world of artistic expression thanks to plunger-driven colour mixing within the machine barrel, where vibrant hues gracefully intertwine, turning every product you create into a unique and mesmerising piece featuring the colour swirls Precious Plastic products are so famous for!

Electronics. Overmolding ensures durability and strain relief for cable connectors, safeguarding cable connections in challenging environmental conditions.

In this article, we’ll take a look at common factors that influence the cost of injection molding, including equipment, labor, and materials – as well as tips for reducing manufacturing costs.

Quality control. Ensuring consistent bonding between different materials can be challenging, and defects like delamination or inconsistent adhesion may arise, requiring meticulous quality control measures.

The product includes all appropriate power switches and warning labels. Please note: This machine is fitted with safety features, however it's important to understand that these machines are dangerous, and proper safety measures must be implemented.

 Overmolding offers versatile solutions to manufacturing challenges by combining different materials to enhance product functionality, durability, ergonomics, and aesthetics. The following are several of the advantages of overmolding.Â

Construction. Safety equipment such as hard hats and tool handles benefit from overmolding, providing impact resistance and improved grip for construction workers.

What an amazing machine! When we first got our Injector our main priority was to make sure the Machine was safe, especially considering the people using it were going to be young men and women with disabilities - But the Pro Series Injector is such an incredible machine that is so safe and efficient - it is by far the most popular machine we have in the factory! Could not recommend enough! 11/10

To get a quote for your overmolding project, start by uploading a part. You can also contact our injection molding experts with any questions or special requirements.Â

Find out about the manufacturing technique used to injection mold a second material over or around a part to create a new one.

Limited material options. Material compatibility is crucial in overmolding, limiting the selection of suitable combinations – and potentially restricting the ability to achieve specific material properties.

What is Delrin and why is it unique among the many manufacturing materials available? Delrin, or POM-H (homopolymer acetal), is used in CNC machining, 3D printing and injection molding to create durable, precise components. This article explores Delrin’s properties and how to get the most out of the material.

Improved aesthetics. Different colors, textures, and finishes can be achieved through overmolding, enhancing the visual appeal of products and enabling branding opportunities.

Reduced assembly. Overmolding combines multiple components into a single piece, reducing the need for complex assembly processes, lowering labor costs, and minimizing the risk of assembly errors.

We offer a dedicated training session for all new Zephyr Bros. machine purchases, available either onsite at PPM or online.

Enhanced functionality. Overmolding allows the integration of different materials with distinct properties, resulting in improved grip, cushioning, insulation, or sealing, enhancing the overall functionality of the product.

Overmolding works by first placing the injection-molded part into a mold. Next, a second material is injected over or around the part. The two materials are then bonded together during the curing process.

Learn what to consider when making a choice between 3D printing and injection molding, the benefits of each manufacturing method, and more.

Applying the following best practices can help ensure successful overmolding, leading to high-quality products with optimal functionality and aesthetics.

How do you optimize part design for injection molding? This complete guide to designing for injection molding provides basic and advanced design tips, including guidelines for creating snap-fits, living hinges and undercuts, and accounting for optimial surface finishes.

Medical equipment. Overmolding is employed in medical device housings, enhancing durability and ergonomic design for instruments like handheld scanners and diagnostic tools.

Aerospace. Within aircraft interiors, overmolding enhances passenger comfort and cockpit functionality, seen in armrests, seat cushions, and control grips.

Packaging. Overmolding contributes to the creation of ergonomic and comfortable grips on packaging machinery handles, improving operator experience and efficiency.

In overmolding, a variety of materials can be used to achieve specific properties and functions. Several common combinations include:

Consider shrinkage. Account for material shrinkage differences between the injection-molded part and overmolded material to prevent warping or dimensional inconsistencies.

Draft angles. Incorporate draft angles to aid in easy part ejection from the mold, reducing the risk of damage during demolding.

Tool design. Design molds with appropriate gating, runner systems, and cooling channels to ensure uniform material flow and efficient part production.

Thermoplastic over thermoplastic. Using two different thermoplastic materials, such as a rigid plastic material like PC and a softer rubber-like material like TPU for improved grip or comfort.

Level up your injection molding knowledge and find practical tips about selecting materials, working with draft angles, and reducing costs.

Overmolded material placement. Position the overmolded material's injection points away from critical features and edges to avoid material entrapment or disruption.

It has also been a fantastic tool for education purposes due to it's simple nature - very easy for kids to visualise the recycling process at schools/events!

While tooling costs can be higher, overmolding often reduces assembly and enhances product lifespan, justifying the investment.

Costly tooling and equipment. The need for specialized molds and injection molding equipment tailored to overmolding can lead to higher initial investment and tooling costs compared to traditional molding processes.

Why is it important to design draft angles for injection molding custom parts? This article covers why draft angles are essential and how to design them better to get the most out of your injection molding designs.

What are the common applications of injection molding? What sets it apart as a manufacturing process? This article covers the key benefits of injection molding and provides insight into whether injection molding is right for your industry’s applications.

Material compatibility. Choose materials that bond well together and have similar melting temperatures to ensure a strong and reliable bond between layers.

Design for bonding. Create proper surface features, undercuts, and interlocking structures to facilitate mechanical bonding between the injection-molded part and the overmolded material.

Various combinations include thermoplastics, elastomers, metals, and silicone, chosen for desired properties like grip, flexibility, or sealing.

Thermoplastic over metal. Coating metal parts with a protective or cushioning plastic layer, such as encasing steel components with PP, to enhance corrosion resistance and reduce noise or vibration.

Robotics. Overmolded grippers provide robotic systems with a balance of flexibility and rigidity, enabling secure handling of diverse objects.

Want to learn more about die casting? In this article, we’ll take a look at the process, its history and current uses, advantages, design guidelines, and more.

Our business has had this machine for three months and in this short time we've been able to garner community support for the program and deliver recycled plastic products to our customers. We've seen huge growth in our recycling program due to this machine.

Australian made: We build high quality machines fit for purpose and compliant with Australian Safety Standards. Knowledge and support: Our machines are built by people who use them! And, if you do happen to need additional assistance, we offer post-purchase support - a pretty important factor when you're investing in equipment.

Avoid sharp corners. Rounded edges and corners help prevent stress concentration and facilitate material flow during the overmolding process.

Overmolding is a manufacturing process that is often used in injection molding, in which a part is encased or covered with a second material – typically a rubber or plastic – to create a single, integrated product. It enhances product durability, grip, aesthetics, and functionality.

What are the most common defects in the injection molding process and how do you avoid them? This article provides six essential design tips for avoid production defects while reducing the cost and lead time of your molded parts.

Find out about the manufacturing technique used to injection mold a second material over or around a part to create a new one.

Proper wall thickness. Maintain consistent and appropriate wall thickness to ensure even material flow and prevent defects like sink marks or voids.

When producing parts with injection molding, understanding the range of materials that are available is crucial. Find out more about those materials, their properties, and factors to consider when choosing a material for injection molded parts.

Overmolding involves placing an injection-molded part into a mold and injecting a second material to bond and create a single, integrated product.

Process complexity. Overmolding involves multiple steps and material transitions, increasing the complexity of the manufacturing process and potentially leading to quality control challenges.

Industrial tools. Overmolding improves ergonomics in handheld power tools, reducing operator fatigue and enhancing control during industrial use.

Machine Type: Manual Power Supply: Single Phase Product Capability: Medium (e.g. Phone Case) Weight (KG): 52 Dimensions (MM): 800L x 300W x 1280H Heating Power (W): 1220 Voltage (V): 240 AC Amperage (A): 6 Cable: IEC Mount (Supplied To Suit Country Of Use) Regulatory Compliance Mark (RCM): Yes

Venting. Integrate venting features in the design to allow air and gases to escape during injection, preventing voids and trapped air pockets.

Want to learn how to design undercuts that don’t cause damage to your parts? Check out our article, which offers tips and tricks for DFM with undercuts, examples of when you might need them, and more. Undercuts in injection-molded parts present a host of challenges to designers and manufacturers. In this article, we’ll take a look at the definition of undercuts, their purpose, applications, and tips for designing parts with them.

Despite its advantages, overmolding presents challenges in terms of design complexity, material compatibility, production costs, quality control, and specialized tooling requirements. Learn more about the challenges in order to overcome them.Â

Want to learn more about exactly how an injection molding machine functions, as well as its individual parts? This article puts injection molding machines under the microscope, with detailed descriptions of their components and an in-depth guide to the injection molding process.

Thermoplastic over elastomer. Combining a rigid plastic such as ABS with a flexible elastomer for products requiring both durability and flexibility, like tool handles or medical devices.

In injection molding, “overmolding” refers to a process where multiple materials are used to create a cohesive, often multi-textured product with improved qualities and versatility. Here’s a guide to using the technique, including how it works, its common industrial uses, and more.

Embark on a journey of boundless creativity with our Pro-Series Injection Machine. Witness the magic as shredded plastic enters the hopper, undergoes a transformative heating process through a precision-engineered barrel, and emerges into your product mould as a bespoke masterpiece. Experience reliable and precise production output, unlocking the potential for extraordinary upcycled creations.

Ensuring proper material bonding, design intricacies, and quality control are challenges in achieving consistent overmolding results.