Any does and don'ts when it comes to overmoulding on aluminium sheet?
Any does and don'ts when it comes to overmoulding on aluminium sheet?
(OP)
I've had a RFQ in from a customer to manufacture a 1+1 injection mould tool to overmould on to an 1mm aluminium veneer trim that fits onto an instrument panel. The substrate is in >PC-ABS<. This part is highly visual once assembled so scratches, blemishes etc are not acceptable!!
I know there are a lot of issues to look out for such as: 1. Difference in shrinkage between aluminium and plastic substrate giving a mismatch condition.
2. Aluminium trim will be damaged/scratched during moulding.
3. Flash
4. Aluminium not bonding to the PC-ABS.
The list could go on. Can anyone give me some ideas on past experiances on do's & don'ts for part and mould design?
Thanks
I know there are a lot of issues to look out for such as: 1. Difference in shrinkage between aluminium and plastic substrate giving a mismatch condition.
2. Aluminium trim will be damaged/scratched during moulding.
3. Flash
4. Aluminium not bonding to the PC-ABS.
The list could go on. Can anyone give me some ideas on past experiances on do's & don'ts for part and mould design?
Thanks






RE: Any does and don'ts when it comes to overmoulding on aluminium sheet?
Is it 2D or 3D?
How will you hold the insert?
Will heat discolor it?
RE: Any does and don'ts when it comes to overmoulding on aluminium sheet?
The parts are 3D, not very complicated.
The plan to hold the insert in place during tool close and injection is firstly to use vacuum to stop the part dropping of during tool close. The next fixing is mechanical by means of Ø4 pins that shut off on the 'B' surface of the aluminium veneer.
lastly I am not sure if heat will discolour it. Do you think this is possible? The finish on the aluminium veneer is supposed to be a bright brushed effect.
Thanks
RE: Any does and don'ts when it comes to overmoulding on aluminium sheet?
When I do a knife edge I always have it on a compression slide. This takes up the small thickness difference in the sub-strate.