Overmolding is a manufacturing process that involves molding one material over another, resulting in one integrated, high-performance component. The rubber overmolding process delivers many benefits, including:
- Enhanced rigidity
- Tight seals, including waterproof seals
- Decreased number of components needed for an assembly
- Maintains seal and assembly alignment
- Produces an extremely strong elastomer bond with the metal substrate, at times stronger than the rubber’s physical properties
- Improved durability that can extend a product’s lifespan
- Ideal for seals, gaskets, poppets, latches, and other components that experience force and movement
At RD Rubber, we specialize in delivering high-quality overmolding capabilities to meet the needs of demanding industries for critical to function applications. Our overmolding capabilities involve molding thermoset elastomers over various substrates including metal and thermoplastic components. Every project is driven by our commitment to provide our customer with engineered quality parts and responsive communication and customer service. Learn more about our overmolding capabilities, techniques, and materials.
Overmolding Capabilities Offered by RD Rubber
RD Rubber Technology Corporation offers complete overmolding capabilities to meet our customers’ custom requirements including type of substrate or insert, overmolded material and process engineering supported by our ISO 9001 and AS 9100 certified quality management system.
Our overmolding capabilities include:
- Process Engineering: We work directly with customers to optimize product manufacturability and quality.
- Material selection: RD Rubber provides material qualification support, compounding per customer design requirements and material testing capabilities.
- Full-scale production: We welcome volume requirements from initial development to first article and volume production.
Comprehensive Rubber Overmolding Processes
To cater to our customer’s unique requirements, RD Rubber implements customized overmolding techniques, each offering unique benefits depending on the application.
The specifics of the rubber overmolding process differ depending on the metal and elastomer used and the end product’s performance goals. However, there are three basic stages to the production process:
- Material preparation: The first stage in the metal insert overmolding process is to select the overmolding materials and prepare them for the bonding process. The metal substrate is thoroughly cleaned using a degreasing agent and then kept away from moisture.
- Substrate surface treatment: Next, a chemical bonding solution is applied to the metal’s surface at a controlled thickness. This can be either a one-step adhesive coating or a two-step primer and adhesive coating. RD Rubber’s chemical bonding solutions comply with ASTM D429 standards. The coating will then dry in a low-humidity, contamination-free environment.
- Overmolding production: After applying the adhesive, the rubber overmolding process can begin. The metal insert and an uncured rubber preform are positioned inside a heated mold that is clamped tightly to fill the cavities with rubber. The rubber bonds to the metal and is then cured into a finished overmolded component.
By matching these techniques to each project, we create components that offer superior performance, durability, and aesthetic appeal. Our approach also ensures that each project is optimized for efficiency and cost-effectiveness.
Materials Used in RD Rubber’s Overmolding Capabilities
At RD Rubber, material selection is a critical aspect of the overmolding process. We offer a wide range of materials, including elastomers like EPDM, nitrile, silicone, fluorosilicone, Viton® and Fluoroelastomer (FKM), each carefully chosen to meet the specific demands of your project. Depending on the application requirements, materials are selected based on their unique benefits, such as high-temperature performance, chemical resistance, durometer, compression set, sealing capabilities, and other properties that your end application demands.
Custom Overmolding Solutions at RD Rubber
We understand every project is unique, so we offer fully customized overmolding solutions. Our team works closely with customers from the initial design phase to ensure that the final product meets all specifications and performance requirements. RD Rubber also can provide material lot traceability, Moving Die Rheometer (MDR), compression set and hardness certificates of conformance and other customized testing of overmolded components in their intended operating conditions. Tests we perform include:
- Adhesion and Bonding
- Environmental (Soak Testing)
- Vacuum (Sealing)
Ready to Enhance Your Products With Rubber Overmolding? Contact RD Rubber Today!
RD Rubber is your trusted partner for your critical function overmolding products. We are ISO 9001:2015 and AS9100:2016 certifies, ITAR and DOD registered and NIST 800-171 compliant. Our expertise, engineered quality processes, and commitment to customer service make us the ideal choice for customers across demanding industries. We understand the critical role that rubber overmolding plays in enhancing the performance of your products, and we’re dedicated to providing innovative solutions that meet your unique needs.
Whether you’re developing a new product, looking to improve an existing one or need additional production capacity, RD Rubber has the experience, technology and capabilities to deliver exceptional results. Request a quote to get started with your overmolding solution.
