Low Pressure Overmoulding

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1 Low Pressure Overmoulding Complete Product Encapsulation IP 67/68 Environmental protection Strain relief and other design features

2 About overmould Original and Best Overmould Ltd has been established for over 10 years specialising in low pressure overmoulding with advanced polyamides for industries that depend on product reliability, compactness and cost efficiency for success. Our business is to turn devices into products - complete and ready to ship. We were the first and are still the UK s leading overmoulding company with the greatest experience in the application of low pressure moulding technology. 1

3 Explore the possibilities. Contact Overmould today. TECHNOMELT Polyamide TECHNOMELT is a unique polyamide designed for the electronics industry. It delivers exceptional insulation properties, great physical strength and excellent adhesion to cable sheaths, metals, plastics and other materials. It is extensively used in aerospace, medical and automotive industries and is now readily available through Overmould, Henkel s UK partner. In house design, consultation, preproduction services and demonstration facilities are based in Bedfordshire, England, as well as machine sales, material sales and expertise, service and support. TECHNOMELT is increasingly used in industry to achieve cost and performance advantages. As a robust alternative to traditional potting and encapsulation techniques, TECHNOMELT brings improved reliability, reduced manufacturing times and ultimately superior products. Polyamide. Protective hotmelt encapsulation even for small and delicate electronic components. 2

4 Advanced Protection for electronic CIRCUITRY Low pressure injection of TECHNOMELT polyamide for electronics encapsulation TECHNOMELT polyamide provides advanced protection for electronic circuitry in tough environments. In just one or two mould steps, assemblies can be converted from delicate electronic structures to robust, ready to market products. The automated processing, throughput and cure time advantages that TECHNOMELT delivers simply cannot be matched by oldergeneration encapsulation methods. Low pressure moulding provides mechanical integrity, protects solder joints from vibration fatigue and the entire assembly from the atmosphere and liquids that could promote corrosion or conductive paths. Technomelt comes in black, amber or clear - with other colours available through secondary processing. Examples assemblies transforming electronic devices to final product through Overmoulds expertise with Henkel Technomelt. 3

5 Because of the unique characteristics of TECHNOMELT the applied mould pressure is very low compared to injection moulding, and so the mould process is gentle on electronic structures - even surface mount components and lead free soldering is safe! Low mould pressure also enables the use of aluminium tooling so project costs are drastically reduced and lead times are cut. Even small batch sizes can take advantage of the many benefits of overmoulding. Designers understand that the advantages of TECHNOMELT go beyond simple enclosures including fixings, strain relief and product identity. Low pressure moulding encases, seals and adds value in one operation. Designing with TECHNOMELT has become state of the art across many electrical and electronics industries increasing reliability, product performance, profit and competitiveness. Moulded Grommit to provide sealing and exceptional strain relief. Rockblock complete electronic encapsulation providing protection to IP67 or higher 4

6 We turn devices into products Versatile application TECHNOMELT is a strong adhesive and will bond with many substrates. For instance, the grip onto PVC is excellent, making it perfect for sealing and anchoring cables. TECHNOMELT also bonds to clean steel, solders and other metals commonly encountered in electronic modules. In fact, in our experience, nothing sticks better! When cool, TECHNOMELT is tough retaining slight flexibility below zero degrees yet good rigidity to 130 degrees or even higher with selected variants. Electrical insulation is excellent at typically 1012/cm and the dielectric strength is 20kv/mm. High performance technical poyamide Low pressure overmoulding of electronics provides a mechanical integration that enables fewer parts, higher reliability and cost savings. By creative involvement during the design phase, other benefits may also be enjoyed such as increased perceived value, additional functions, security of IP, electrical insulation and improved user friendliness. Product advantages with TECHNOMELT TECHNOMELT is a high performance technical polyamide designed to flow at low temperatures, and therefore low pressures. Delicate electronic structures can therefore be encapsulated without disturbance. The tooling can be made from aluminium, reducing costs and shortening lead times. Applications include component protection, reliability enhancement, insulation and security, whilst adding mechanical features and product appeal. Component Support Strain Relief No vibration damage Advantages of two-stage moulding Many applications require only one injection process to complete. Some applications that are highly complex often benefit from two stages of moulding. The first for primary or bulk encapsulation, the second to ensure a uniform allround thickness, coverage and finish. Both stages can often be incorporated into a single mould tool. Environmental protection Location features 5

7 Low pressure overmoulding improves product performance TECHNOMELT is increasingly used in automotive, aerospace, medical, and communication industries to achieve cost and performance advantages. By rethinking conventional packaging and eliminating potting and traditional encapsulation, TECHNOMELT, together with low pressure moulding, delivers improved reliability, reduced manufacturing time and improved product performance. Moldman Machines Overmould Ltd is the sole European distributor for MoldMan low pressure moulding machines and Buhnen hand applicators for LPM. The MoldMan series represents the most solid, reliable, well-designed and consistently performing machines on the market. Full spares back up and support is directly available from our headquarters in the UK. In House Tooling Overmould Ltd has made significant investments in the in-house 3D design of tooling and CNC machining of mould tools. We offer fast turnaround at competitive pricing. About us Overmould Ltd, located in Bedfordshire in the UK, has been established for over 10 years specialising in supplying world class manufacturers with low pressure overmoulding solutions using Henkels advanced TECHNOMELT polyamides. Our global customers rely on us for product reliability, performance and cost efficiency. Our business turns devices into a products - complete and ready to ship in one hit. Protecting electronics since 2003 Overmould Ltd was founded in 2003 as a sister company to Cirris Solutions, (founded 1990), to supply a unique new subcontract low pressure overmoulding service, polyamide (hotmelt) materials (made by Henkel) and equipment, (made by Cavist & Buhnen). It is a privately owned company with an excellent global reputation and supplies customers as diverse as British Aerospace, McLaren, Nissan and Olympus. Moldman 8200 Low Pressure Moulding machine. In house tooling. 6

8 Customers Include Amphenol Limited Automobili Lamborghini S.p.A BAE Systems BCA Leisure Limited Beru F1 Systems Bombardier Transportation Cirris Systems Corp. CMR (UK) Ltd Contronik limited Convert Ltd Fischer Connectors Ltd GE Aviation GE Healthcare Gem Cable Solutions Ltd Genalog Ltd Goodrich Control Systems Ltd Harting Integrated Solutions Ltd Helmet integrated Systems Ltd Hidalgo Ltd HMGCC Honda Connectors Ltd Hunter Cable Assembly Ltd Lockheed Martin UK McLaren F1 Marine Rescue Technologies Ltd Medical Research Council Meggit Defence Systems Ltd. Meggitt Aircraft Braking PANALUX LIMITED R.A Labone & Co Ltd Red Bull Technology Ltd Renishaw PLC Rolls-Royce Roxel (Uk Rocket Motors ) Ltd Sanmina-SCI Schrader Electronics Siemens plc. Thales Air Defence Thales Rail Signalling Solutions Ltd Time 24 Ltd Tyco Electronics UK Ltd White Light Ltd Williams Grand Prix Ltd Overmould provided us with excellent technical advice and were able to practically demonstrate the technical feasibility of a demanding overmoulding project. We will have no hesitation in using their services again for future projects. Chris Young - Managing Director - R A Labone & Co Ltd We went looking for expertise in low pressure moulding. We found it in Overmould. Ian Dole - Selex Communications overmould strives to reach the highest standards both technically and in customer care so that our products and services meet or surpass expectation. Overmould Ltd Unit 4 Commerce Way Stanbridge Road Leighton Buzzard Bedfordshire LU7 4RW Telephone: FAX: sales@overmould.com WEB: