Silicone Overmolding onto Metal or Plastic
Overmolding process for VMQ, LSR, or HCR silicone onto metallic or thermoplastic inserts. Permanent chemical or mechanical bond. High precision, sealing performance, and thermal resistance. Production in ISO 8 cleanroom or industrial environment under ISO 9001 and ISO 13485 control.
Process Principle
Silicone overmolding consists of injecting or compressing silicone directly onto a pre-prepared metallic or plastic insert. This process creates a permanent chemical or mechanical bond, ensuring resistance, sealing performance, and dimensional precision.
Materials and Formulations
Can be performed with VMQ, HCR, or LSR silicone depending on project requirements. Available formulations: medical-grade, food-grade, fire-retardant, conductive, antistatic, or high-temperature. Compliant with FDA 21 CFR 177.2600, EC 1935/2004, EN 45545-2, UL94, USP VI, and ISO 10993.
Inserts and Compatibilities
Accepts inserts made of stainless steel, aluminum, brass, PA, PEEK, PPS, PC, PMMA, or ABS. Option for chemical primers or surface treatments to maximize adhesion. Configurable for dual injection or 2K molding according to design.
Production Environments
Production in an ISO 8 cleanroom for medical-pharmaceutical parts or an industrial environment for technical components. Audited and traceable processes under ISO 9001 and ISO 13485 with control of adhesion, sealing performance, and thermal resistance.
Product Gallery
Key Technical Data
Typical values obtained according to series datasheets (1, 2, 9, 12) and indicated standards. May vary based on hardness, formulation, and raw material. Final validation is the customer's responsibility.
| Property | Typical Values | Standard |
|---|---|---|
| Hardness (Shore A) | 20 – 90 (núcleo habitual: 40–70) | ISO 7619-1 |
| Tensile Strength | 6 – 9 MPa (según dureza) | ISO 37 |
| Elongation at Break | 300 – 700 % (blandos hasta 1000 %) | ISO 37 |
| Tear Resistance (Type C) | 15 – 30 kN/m (alto desgarro hasta 40 kN/m) | ISO 34-1 |
| Density | 1,11 – 1,20 g/cm³ (extremos 1,07 – 1,23) | ISO 2781 |
| Working Temperature | –60…+200 °C (up to +300 °C in thermal series) | — |
| Tolerances | Molding Class M2 | ISO 3302-1 |
| Sectoral (On Request) | FDA / CE 1935/2004 / BfR / EN 45545-2 / RoHS / REACH / UL94 | — |
Certifications and Regulatory Compliance in Silicone Molding
Every molding batch is manufactured under strict validation protocols, guaranteeing conformity with international standards and integral traceability of the material and the mold.
Main Certifications
- ISO 9001:2015 – Quality Management System
- ISO 13485:2016 – Medical Devices
- EN 9100 – Aerospace and Defense
- GMP – Good Manufacturing Practices
- ISO 10993 – Medical Biocompatibility
- USP Class VI – Pharmaceutical Biocompatibility
Regulatory Compliance
- FDA 21 CFR 177.2600 – Food Contact
- EC 1935/2004 – Materials in Contact with Food
- EN 45545-2 – Railway Fire Protection
- UL94 – Material Flammability
- ISO 10993 and USP Class VI – Medical and Pharmaceutical Biocompatibility
- REACH (1907/2006) and RoHS (2015/863) – Chemical and Electrical Substances
Main Application Sectors
Key Applications
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Silicone–metal or silicone–plastic hybrid parts
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Overmoulded gaskets, valves, or membranes
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Sealed connectors and electronic encapsulation
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Integrated medical, optical components, or sensors
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Precision technical parts with structural function
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Sealing for cable glands and bulkhead fittings on metal housings (IP sealing)
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Handles and ergonomic grips on surgical instruments or tools
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Encapsulation of temperature and humidity sensors in stainless steel bodies
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Battery connectors and electrical terminals overmoulded (Fire-retardant/Conductive)
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Buttons, keypads, and tactile elements on plastic housings
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Seat valves overmoulded on PEEK or PPS bodies (Chemical resistance)
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Sealing rings on metal flanges for food pipework
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Cushioning components on metal structures in motors
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Protective covers on cameras and optical equipment (UV resistance)
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Cable and wiring harness sealing in automotive and railway connectors
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Pistons with overmoulded silicone tip for precision pumps
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Seals for access lids on aluminium frames
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Membrane gaskets on plastic bodies for air regulators
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Magnet and solenoid encapsulation in actuators (Insulation)
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Medical devices with silicone on thermoplastic moulding (USP VI)
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Hybrid parts for interface sealing in aerospace equipment
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Functional buttons with overmoulded colour legend
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Watertight connectors for submersible or high-pressure equipment
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Sealing for in-vitro diagnostic equipment housings (LSR on Plastic)
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Safety closure components on tank lids
Manufacturing and Delivery Options
- Geometries: Total or partial overmolding, 2K, or multi-layer
- Materials: VMQ, HCR, or LSR depending on application
- Inserts: Steel, aluminum, brass, PEEK, PPS, PA, PC, ABS
- Formulations: Medical-grade, Food-grade, Fire-retardant, Conductive, High-temperature
- Production: Industrial or ISO 8 Cleanroom
- Delivery: Assembled, tested, and certified parts
- Entrega: piezas ensambladas, ensayadas y certificadas
Product Selection Matrix
| Customer Requirement | Recommended Solution |
|---|---|
| Overmolded technical parts | Overmolding |
| Medical or optical microcomponents | LSR Injection Molding |
| High-precision series production | HCR Injection Molding |
| Prototypes or large-sized parts | Compression Molding |
| Prototipos o piezas de gran tamaño | Compression Molding |
Technical Conclusion and Recommendations
Silicone overmolding from ProSilicones64 allows elastomers to be integrated with metals or thermoplastics, achieving resistant, sealed, and high-precision bonds.
Each project is developed under ISO 9001 and ISO 13485 control, with certified formulations (FDA, EC 1935/2004, EN 45545-2, UL94, USP VI, ISO 10993) and traceable production in an ISO 8 cleanroom.
An advanced technology that combines materials engineering, molding precision, and industrial reliability, consolidating ProSilicones64 as a European benchmark in technical overmolding.
Una tecnología avanzada que combina ingeniería de materiales, precisión de moldeo y fiabilidad industrial.
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