TPU Overmolding Service | Custom Soft-Touch Solutions

What is TPU Overmolding?

TPU overmoulding is a special injection moulding process in which thermoplastic polyurethane (TPU) is molded onto a substrate, e.g., plastic, metal, or other rigid material. This is done to produce one integrated part that provides greater grip, shock absorption, and functional aesthetics.

As compared to traditional molding, TPU overmolding provides TPU-to-plastic bonding or TPU-to-metal bonding with high precision, hence suitable in any application of soft-touch surfaces, ergonomic design, and interfaces that are durable.

The main TPU Overmolding advantages are:

• Improvement in grip and feel.
• Better contact resistance and longevity.
• Less assembly and cost of labor.
• It includes the smooth integration of various materials.
• Extravagant finish and beauty.

It offers the professional TPU overmolding service, in which decades of experience are combined with the use of the latest robotic equipment, multi-shot molding, and measuring injection molding of TPUs, which guarantees the quality of all production batches.

TPU Overmolding Service: Soft-Touch and Multi-Material Components

• The need for TPU overmolding service in the constantly changing manufacturing world has increased manifold. The electronics and automotive industry, medical devices, and consumer products are increasingly relying on the use of TPU overmolding to manufacture components that not only appear attractive but also last long, are ergonomic, and with superior functionalities.
• Having the ideal combination of engineering and material science, SunOn Mould provides a complete range of custom TPU services to suit the needs of large-volume production and small-volume industrial use.

How TPU Overmolding Works?

The TPU overmolding technique consists of some technical steps to produce high-quality, reliable components:

• Mold Cavity Design for TPU

Every successful TPU overmolded part is based on the accuracy of the design of the mold cavity. Placing the gates, the parting lines, and managing the tolerance is done carefully to ensure perfection by SunOn engineers. TPU overmolding. Mold flow models can be used to predict the behavior of resin, its shrinkage, and cooling trends.

• Insert Preparation and Material Preparation

Robotic insert loading systems are used to place components precisely into the mold, like metal inserts, plastic bases, or electronic housings. Preparation of the TPU material is then done so that it has maximum hardness, flexibility, and strength of bonding strength.

• TPU Injection and Bonding

Molten TPU is injected onto the substrate and bonds well with the substrate. SunOn applies thermoplastic polyurethane elastomers that give heat-stable TPU molding, great elasticity, and durable performance.

• Multi-Overmolding, Multi-Material, and Multi-Shot.

The plant of SunOn is used to provide the multi-shot TPU, 2K injection molding, functions of complex components that have a design of dual color, functional soft-touch zones, and rigid components. This will remove secondary assembly and improve product performance.

• Cooling, Ejection, and Quality Inspection

Components are then molded, cooled, and ejected. The quality is checked on the basis of cycle time efficiency index, surface finish testing, and structural integrity tests, by which all parts are composed to the ISO-certified TPU overmolding company standards.

TPU Overmolding Applications

TPU overmolding is used in various industries because of its flexibility and characteristics of the material.

• Electronics

SunOn produces TPU overmold of electronic cases, wearable’s and keypads. TPU offers shock absorption, slip resistance, and ergonomic feel, which are crucial to gadgets and professional electronics used by consumers.

• Automotive

TPU overmold grip solutions are advantageous to automotive parts, such as dashboard switches, handles, grips, and sealing parts. The process of metal to TPU overmolding at SunOn is very accurate, which means that the services will be trustworthy even in extreme circumstances.

• Medical Devices

TPU is used as a medical device in medical instruments, protective casings, and surgical tools. The technology ensures cleanroom production, excellent tolerances, and safety and performance of biocompatible materials.

• Consumer Products

TPU overmolding is used to improve household items, soft-touch handles to tools, and protective enclosures, providing services of durability, comfort, and high-quality appearance.

• Industrial Equipment

Industrial TPU overmolding can be used in protective covers as well as ergonomic grips, as well as multi-material housings of industrial machines, enhancing impact resistance and the life cycle of parts.

2K Injection Mould Technology in SunOn

The main distinction is the 2K injection mould technology at SunOn, which is also known as double-shot injection or two-component injection moulding. It enables two materials or colors to be injected one after the other into the same mold, producing a whole part of increased strength and aesthetics.

Features:

• Plastic combinations: TPU + ABS, PC + PC, soft + hard plastic.
• Flawless connection of two substances.
• Low and high-volume run production of high efficiency.
• Ergonomic and smooth finishes.

Applications:

• Car Motive: Automotive handles, automotive dashboard, seals.
• Medical: Hand tool grips, sheaths.
• Electronics: Phone cases, keypads, earphones, wearables.
• Household: Kitchenware, dishwasher, oven, and refrigerators.
• Industrial: industrialized covers, tough casings.

Benefits:

• Minimizes assembly processes and labor expenses.
• Increases product aesthetics through multi-material designs.
• Offers more solid and robust parts.
• Quick cycle time on large-scale production.

TPU Overmolding Tooling and Equipment

The current facility of SunOn has:

• Accuracy: TPU mold to be made.
• High-grade steel molds are CNC-machined.
• Robot TPU overmolding machines.
• Two-shot and multi-shot injection molding machines.
• Mold flow simulation of optimum cycle times.

These abilities guarantee steady soft-touch injection modelling, flawless TPU elastomer over modelling, and high-grade tailor-made TPU components.

Professional TPU Overmolding Services Advantages

When comparing the outcomes of a professional TPU overmolding, such as SunOn:

• Existence of high precision and tolerance.
• Better grip and ergonomics of products.
• Bonding strength of long-lasting durability with TPU material.
• Less wear and tear on the products.
• Removed secondary assembly processes.
• Volume and small-volume production capacity.
• OEMs and industrial customers OEMs and industrial solutions.

SunOn is considered the most accepted TPU overmolding service provider with technical knowledge, as well as global coverage and creativity.

Conclusion

TPU overmolding service is a groundbreaking production method, which incorporates material development/innovation, ergonomic designing, and accuracy engineering. We are a pioneering company in terms of manufacturing custom TPU overmolding, soft-touch overmolding, and 2K injection moulding, and provide high-quality and durable, and functional components in the world. SunOn has decades of experience, sophisticated robot systems, and skilled engineering, and offers affordable, dependable, and high-performance TPU overmolding services to any industry.