Specialized Overmold Tooling Systems Developed to Meet Complex Mold Requirements and Enhance Manufacturing Precision

• Part Name: Cordless power drill two-color housing
• Molding Process: Rotary two-shot injection molding (Hard substrate + Soft TPE overmolding)
• Material Matching
  • Hard base material: ABS / PA66+GF / PP+GF
  • Soft grip material: TPE / TPR elastomer
• Structural Features: Built-in motor compartment, ventilation grille slots, trigger opening, battery connection base, ergonomic curved handle
• Surface Requirements: Uniform texture, sharp two-color dividing line, no flash, no delamination, anti-slip grain on grip zone

✅ Rotary Two-Color Mould Structure Two-shot rotary plate mould. First shot inject rigid plastic main housing; second shot overmold soft TPE in one cycle. Higher productivity than separate secondary bonding process.

✅ Precise Sealing for Clear Color Boundary Special edge sealing design at the hard/soft junction to prevent material overflow, ensure neat separation line between two colors, eliminate burr and color mixing defects.

✅ Anti-Delamination Structural Design Optimize undercut interlock structure on hard plastic substrate to realize mechanical locking between hard plastic and TPE layer, effectively avoid peeling under long-time vibration during tool operation.

✅ Precision Slider & Lifter Mechanism Multiple slides and lifters for complex internal undercuts, ventilation slots and trigger cutouts. Stable demolding without scratching the textured surface.

✅ Optimized Balanced Cooling System Distributed conformal cooling channels covering motor housing, handle and thick boss positions. Stabilize molding cycle, reduce housing warpage, shrinkage and sink marks.

✅ Custom Texture Etching Service Cavity surface can be customized with anti-slip leather grain or linear texture on grip area to improve hand grip comfort.

✅ High-performance Mould Steel

• Cavity & Core: 718H / P20HH / S136H
• Standard Service Life: 500,000 ~ 1,000,000 shots
• Suitable for long-term mass production of reinforced engineering plastics and TPE elastomers

• Cordless electric drill / impact drill housing
• Rechargeable screwdriver plastic shell
• Handheld power tool & garden power tool two-color handle housings

1. Pre-sales DFM analysis: assess undercut, demolding risk, TPE bonding stability and two-color dividing line layout
2. Complete 3D mould design + 2D engineering drawings, BOM list output
3. CNC machining, EDM, wire cutting, surface texture etching
4. Mould assembly, trial molding, sample dimension & appearance validation
5. Mould optimization to solve delamination, flash, warpage and surface defects
6. Lifetime remote technical support and spare parts supply