Overmould Ltd

 

Engineering Solutions Ltd is the UK’s leading sub contract manufacturer of low pressure injection mouldings. We specialise in moulding directly on to electronic assemblies such as PCB’s, sensors and other types of sensitive components to create a completely sealed and encapsulated product.

We are pleased to be the UK partner for Henkel’s Macromelt polyamides and provide outstanding solutions that meet all kinds of manufacturing demands. Our excellent relationship with Henkel has been forged over a number of years and has enabled us to provide customers with manufacturing solutions featuring Henkel’s high quality engineering adhesives combined with our own excellent design and application skills.

We have the facilities and capabilities to provide large batch production runs as well as small batches for prototype and development projects.

Please visit our website to find out more about our excellent services. Alternatively, please contact us directly at Engineering Solutions with your enquiries and we will provide all the information and advice you may need.

 

Contract Moulding

Our highly skilled team carries our low pressure overmoulding using Henkel’s excellent Macromelt®. Low pressure overmoulding  is suitable for a range of applications and is a process that provides designers with distinct product advantages in both mechanical and electrical applications. Our highly skilled team works with aluminium mould tool sets in order to achieve great results. Our acclaimed low pressure overmoulding process is used to provide solutions for hundreds of manufacturers. Please contact our friendly team at Engineering Solutions to find out more about low pressure overmoulding and its advantages. Images are available to view in our online Applications Gallery.

Moldman 4000

The Moldman™ 4000 machine is designed specifically for low pressure molding and is ideal for prototyping and lower volume production quantities. The manually operated machine provides users with all of the features necessary for over-molding a wide range of circuit boards, connectors and strain relief. The Moldman™ 4000 features our proprietary pressure control system which controls volumes and pressure. These integrated machines do not have heated hoses, exposed heated joints or exposed moving injection nozzles making them easy to maintain. Please download and view the Moldman™ 4000 Specification document on our website.

Moldman 8200

The Moldman™ 8200 is designed specifically for high volume manufacturing and also features our proprietary pressure control system. The Moldman™ 8200 is an interchangeable unit which enables users to go from one compound to another or to keep an extra melt unit as back-up. It can run two melt units at the same time. Features of the Moldman™ 8200 include: easy access fill lid, auto-fill mechanism (optional), permanent nozzle engagement to upper mold-half, high capacity heated hose, easy access for filter exchange, high capacity precision gear pump, pressure transducer for closed loop pressure control, servo-electric pump control and melt unit on casters for easy exchange when running different materials.

HB-500 ESL

The HB-500 ESL handgun has been expertly designed and manufactured for simple and safe sample manufacturing. It features a melting tank that is integrated into the handgun and an interchangeable nozzle geometry that enables the HB-500 ESL to be used in a wide range of applications. Various accessories can be added to create a complete workstation system from the HB-500 ESL.
 
Technical data HB-500
Working temperature: max. 250 ° C
Air pressure: 0,55 MPa / 5,0 bar
Injection pressure: 0,15 - 0,55 MPa / 1,5 - 5,5 bar
Power supply: 230 V / 50 Hz.
Power: 350 W
Tank volume: 200 ccm
Weight: 10 kg
Dimensions: W 700 mm H 200 mm D 380 mm

HB-4070

The HB-4070 has been designed and manufactured to suit small to medium volume manufacturing. The unit features a seven litre melt tank and variable speed gear pump and provides users with the option of using between one and four heated hoses. This means that up to four workstations can be created to mould simultaneously leading to improved productivity and reduced cycle times. The HB-4070 offers a greater melting capacity than the HB500 handgun and features individual temperature control for the melt tank, heated hose and handguns. The HB-4070 is fully CE compliant.

Applications

Please visit our website to view our Applications Gallery. Here you can view a range of examples of Macromelt® solutions. Simply move the cursor over the images to see them overmoulded and read descriptions to find out how the results were achieved. For further information or advice regarding overmoulding, please contact us at Engineering Solutions Ltd and we will be happy to provide all the information you may need.

Materials

Henkel is the world leader in high performance adhesive materials and provides the industry with innovative, specially-modified thermoplastic polyamide hot melts created specifically for low pressure moulding. Henkel’s Macromelt® low pressure molding materials melt and flow at low viscosities (1,000 to 10,000 cps) facilitating the low injection pressure process. Macromelt® offers excellent adhesion to a range of substrates including PVC, PA6.6, PUR and PP. It bonds to form a watertight and chemical seal. The hot melts cure quickly by cooling which means there are no toxic fumes and cycle times are short.

Mould Sets

Engineering Solutions provides customers with complete project solutions from design to prototype stages through to end production. Our mould sets for low pressure moulding are largely manufactured from aluminium. We also use polyamide moulding materials from Henkel which are non-abrasive and combined with low injection pressures lead to a long and cost-effective operational life of the mould set.  Our mould machines are designed to meet various mould tool sizes and do not require any cross drilling for cooling. Most production mould sets use ejector systems and release agents may be required.

Manuals & Brochures

Low Pressure Overmoulding Brochure

MoldMan Equipment Brochure

OptiMel Equipment Brochure

Overmould 470 Gear Pump Brochure

Overmould Handheld and Benchtop Equipment Brochure