Overmolding

Custom Overmolding Services

Custom Overmolding Services at JIAHUI offer exceptional quality. With a steadfast commitment to excellence, we provide top-notch solutions for all your over-molding needs. Our approach integrates cutting-edge technology with seasoned craftsmanship to offer products that fulfill the most stringent standards within the industry.

With a state-of-the-art facility and a track record of successful projects, JIAHUI is your trusted partner for custom overmolding services. From concept to completion, we ensure attention to detail, durability, and functionality in every product we produce. Experience the pinnacle of quality with JIAHUI’s Custom overmolding Services. Your satisfaction is our driving force.

  • Material Combination Advantage
  • Superior Shock Absorption
  • Cost-Efficient Production
Overmolding - https://jiahuicustom.com/

What’s Overmolding Process?

Overmolding is an advanced injection molding process that revolutionizes product design and functionality by layering rubber-like TPE plastic over an existing substrate. This dynamic technique finds applications in a range of industries, from enhancing grip and dampening vibrations to improving sealing and comfort. The process begins with meticulous material selection, ensuring the TPE overmold and substrate compatibility. Factors like adhesion, hardness, and friction are considered to achieve optimal results. During injection, two primary methods are employed: manual and two-shot molding.

Manual molding involves injection molding the substrate and then hand-loading it into a separate mold for over-molding. Two-shot molding employs advanced machinery to mold the substrate and apply the overmold continuously. Overmolding yields numerous benefits, including improved grip, enhanced comfort, and extended product lifespan due to better shock absorption. The technique’s versatility enables the creation of products with unique shapes and textures, elevating both functionality and aesthetics. From ergonomic handles to electronics protection, overmolding’s impact is far-reaching, enhancing product quality across various sectors.

Our Qualification For Overmolding Service

At JIAHUI, we prioritize a personalized approach to meet your distinctive needs. We offer long-term prototype overmolding solutions that seamlessly guide engineering experts and project managers from design to production. Our strategy synergizes cost-effective mold tooling with cutting-edge tech-driven overmolding services, ensuring the creation of high-quality parts that exceed expectations.

Backed by certified domestic facilities and a robust supply chain system, we accelerate product development timelines, efficiently bridging the production of your over-molded components. Certified factories, meticulous in-process inspections, and dimensional verifications post-production assure the unwavering quality of custom molded parts, regardless of complexity, ensuring high precision.

Collaborate with our seasoned specialists, boasting over years of experience in the injection molding domain. Our streamlined process efficiently transitions from prototyping to full-fledged production. Partner with us and experience the power of tailor-made overmolding solutions that elevate your products’ quality, functionality, and aesthetic appeal.

Manufacturing Process

Our meticulous manufacturing process begins with material selection and precise design considerations. Injection of the substrate, manual or two-shot, is complemented by certified inspections ensuring consistent, high-quality, over-molded parts.

Material Weight Size Limit Surface Finish Tolerance
PMMA 0.012~1KG 500mmx500mmx300mm Ra1.6µm~0.025µm 0.04~0.60mm
PVC 0.012~1KG 500mmx500mmx300mm Ra3.2µm~0.2µm 0.06~0.80mm
ABS 0.012~1KG 500mmx500mmx300mm Ra1.6µm~0.025µm 0.04~0.60mm
PP 0.012~1KG 500mmx500mmx300mm Ra1.6µm~0.1µm 0.12~1.60mm
PA 0.012~1KG 500mmx500mmx300mm Ra1.6µm~0.1µm 0.06~0.80mm
PE 0.012~1KG 500mmx500mmx300mm Ra6.3µm~0.1µm 0.12~1.60mm
PS 0.012~1KG 500mmx500mmx300mm Ra3.2µm~0.05µm 0.04~0.60mm
PC 0.012~1KG 500mmx500mmx300mm Ra1.6µm~0.05µm 0.04~0.60mm

Our Overmolding Production Capabilities

Our advanced over-molding production capabilities combine expert material compatibility, efficient processes, and stringent quality checks. From low to high volumes, we excel in delivering custom over-molded parts that exhibit exceptional grip, durability, and aesthetics, meeting diverse industry needs with precision and excellence.

Materials for Overmolding Parts

Our carefully curated selection of materials for over-molding parts ensures optimal bonding, hardness, and friction properties. We offer a diverse range of TPE plastics tailored to specific applications, guaranteeing reliable adhesion and enhanced product performance.

  • ABS
  • PVC
  • PE
  • PP
  • POM
  • PA
  • PC
  • PEEK

ABSABS

ABS is a thermoplastic material known for its strength, impact resistance, and toughness. It is widely used in various industries for its excellent mechanical properties, ease of processing, and versatility. ABS is commonly found in applications such as automotive parts, toys, electronics, and household appliances.

Characteristics

  • High-impact resistance and toughness
  • Good dimensional stability
  • Excellent chemical resistance
  • Easy to process and mold
  • Versatile and used in various applications, including automotive, electronics, and consumer goods.

 

PVCPVC

PVC is a versatile thermoplastic material known for its durability, chemical resistance, and cost-effectiveness. It is commonly used in construction, plumbing, electrical insulation, and various consumer products. PVC can be flexible or rigid, making it suitable for multiple applications.

Characteristics

  • Excellent chemical resistance
  • High durability and long lifespan, even in harsh conditions.
  • Good electrical insulating properties
  • Versatile and can be rigid or flexible
  • Cost-effective and widely available

 

PEPE

PE is a widely used thermoplastic material known for its excellent chemical resistance, low moisture absorption, and high impact strength. It is lightweight, flexible, and has good electrical insulating properties. PE is commonly used in packaging, pipes, automotive components, and various consumer products.

Characteristics

  • Excellent chemical resistance
  • High-impact strength and toughness
  • Low moisture absorption
  • Good electrical insulating properties
  • Lightweight and flexible

 

PPPP

PP is a thermoplastic material known for its high chemical resistance, low density, and good thermal stability. It is lightweight, rigid, and has excellent moisture resistance. PP is commonly used in automotive parts, packaging, laboratory equipment, and various consumer products due to its versatility and cost-effectiveness.

Characteristics

  • High chemical resistance
  • Low density
  • Excellent moisture resistance
  • Good thermal stability
  • Versatile and cost-effective

 

POMPOM

POM, also known as acetal or Delrin, is a high-performance engineering thermoplastic known for its excellent strength, stiffness, and dimensional stability. It has low friction, good wear resistance, and is resistant to moisture, chemicals, and solvents. POM is commonly used in mechanical and precision parts, automotive components, and electrical applications.

Characteristics

  • High strength and stiffness
  • Low friction and wear resistance
  • Excellent dimensional stability
  • Good chemical resistance
  • Low water absorption

 

PAPA

PA, commonly known as nylon, is a versatile thermoplastic material with excellent mechanical properties. It offers high strength, toughness, abrasion resistance, good chemical resistance, and dimensional stability. PA is widely used in various industries for applications such as electrical components, consumer goods, and automotive parts.

Characteristics

  • High tensile strength and toughness
  • Good chemical resistance
  • Low friction and wear resistance
  • Excellent dimensional stability
  • Good thermal stability

 

PCPC

PC is a durable and transparent thermoplastic material known for its high impact resistance and optical clarity. It has good electrical insulating properties, excellent dimensional stability, and can bear a wide range of temperature. PC is commonly used in safety glasses, automotive components, and electronic enclosures.

Characteristics

  • High impact resistance
  • Optical clarity
  • Good dimensional stability
  • Electrical insulation
  • Wide temperature range

 

PEEKPEEK

PEEK is a high-performance thermoplastic material known for its exceptional mechanical properties, chemical resistance, and high-temperature resistance. It offers excellent strength, stiffness, and dimensional stability, making it suitable for demanding aerospace, automotive, and medical applications.

Characteristics

  • High-temperature resistance
  • Excellent chemical resistance
  • High mechanical strength
  • Low flammability
  • Biocompatibility

 

Surface Treatment For Overmolding Parts

Highlighting the significance of surface treatment, we elevate overmolding outcomes through various techniques. With a comprehensive range of options, we ensure that each part performs exceptionally and meets diverse requirements.

Name
Product
Description
Materials
Color
Texture

In-Mold Decoration(IMD)

IMD_Overmolding - https://jiahuicustom.com/

In-mold decoration (IMD) is a surface finish method where decorative patterns or designs are applied to a plastic part during molding. This technique eliminates the need for secondary painting or printing operations, resulting in a durable, high-quality, and visually appealing finish.

PET, PMMA, ABS, PC, PC+PMMA, ABS+PMMA

Black, Grey, Red, Blue, Gold, White, Silver, Purple

Smooth, Matte finish

Bead Blasting

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Bead blasting in surface treatment is a process where fine abrasive particles, such as glass beads or ceramic media, are propelled at high speed onto a surface using compressed air. This abrasive action helps to remove rust, paint, or other contaminants, leaving behind a clean and textured surface finish.

PC, PMMA, ABS, PU, TEFLON, Rubber

Clear

Smooth, Matte finish

Out-Mold Decoration(OMD)

OMD_Overmolding - https://jiahuicustom.com/

Out-mold decoration (OMD) is a surface finish method where decorative elements, such as graphics or patterns, are applied to the outer surface of a molded part. This technique involves placing a pre-printed film or foil onto the part's surface and then using heat and pressure to bond the decoration, creating a visually appealing and durable finish.

PET, PMMA, ABS, PC, PC+PMMA, ABS+PMMA

Black, Grey, Red, Blue, Gold, White, Silver, Purple

Smooth, Matte finish

Electroplating

Electroplating_Overmolding - https://jiahuicustom.com/

Electroplating in surface treatment is when a metal coating is applied to a conductive surface through an electrochemical reaction. It involves immersing the object to be plated in a solution containing metal ions and using an electric current to deposit a metal layer onto the surface.

ABS, PP, PSF, PC, PVC, PS, PF, EP, PA, PTFE

White, Black, Grey, Red, Yellow, Blue, Green, Gold, Silver, Bronze

Smooth, Semi-matte, Matte finish

Polishing

Polishing_Overmolding - https://jiahuicustom.com/

Polishing is the process of creating a shiny and smooth surface, either through physical rubbing of the part or by chemical interference. This process produces a surface with significant specular reflection but can reduce diffuse reflection in some materials.

PP, PMMA, PC, PS

Clear

Smooth, Semi-smooth, Matte, Textured finish

Laser Carving

Laser Carving_Overmolding - https://jiahuicustom.com/

Laser carving is a surface finish method that utilizes laser technology to etch or engrave intricate designs onto a material's surface. It offers precise and detailed patterns, making it suitable for aesthetic enhancements or functional purposes, and is commonly used in various industries such as manufacturing, jewelry, and art.

PP, PE, ABS, PC, PC+ABS, PA6, PA12, PS, PBT, PET, PVC, POM, SEBS, TPU, PU, TPE, PPS

Black, Grey, White, Yellow, Red, Blue, Green, Gold, Silver, Purple

Smooth, Matte finish

Printing

Printing_Overmolding - https://jiahuicustom.com/

Printing is a surface finish method that involves transferring ink or other pigments onto a material's surface to create images, text, or patterns. It is a versatile technique used in various industries, such as packaging, advertising, textiles, and art, to add visual appeal and convey information.

PE, PP, PVC, ABS, PET, PS, PVA, PC, CA, NY

Black, Grey, White, Yellow, Red, Blue, Green, Gold, Silver, Purple

Smooth, Matte finish

Non-conductive vacuum plating(NCVM)

Non-conductive vacuum plating (NCVM) is a surface finish technique that applies a thin metallic coating on non-conductive materials. It involves a vacuum deposition process to vaporize and deposit metal ions onto the substrate, enhancing conductivity and providing an attractive finish.

PC, PC+ABS, PC+GF(10%), ABS, PMMA, NYLON, PVC, PE, PA, PP

Black, Grey, White, Yellow, Red, Blue, Green, Gold, Silver, Purple

Smooth, Matte, Semi-transparent finish

Texturing

Texturing_Overmolding - https://jiahuicustom.com/

Texturing is a surface treatment process that involves creating patterns, textures, or designs on the surface of a material. It is typically done to enhance the appearance, improve grip, or provide functional benefits such as reducing friction or improving adhesion.

PA, ABS, PE, PP, PET, PC, PVC, PS, PF, EP

Black, Grey, White, Yellow, Red, Blue, Green, Gold, Silver, Purple

Smooth, Buffed, Matte finish

Painting

Painting is especially suitable for the surface of the primary material of metal. It will strengthen the material's moistureproof& rust prevention functions and enhance its compression resistance and internal structural stability.

PA, ABS, PE, PP, PET, PC, PVC, PS, PF, EP

Black, Grey, White, Yellow, Red, Blue, Green, Gold, Silver, Purple

Smooth, Matte finish

Excellent Overmolding Services

Discover endless choices for your over-molding order with us and customize it perfectly.

Typical Overmolding Products

Overmolding - https://jiahuicustom.com/

FAQs Related To Overmolding

A: The overmolding process, also known as two-shot molding or multi-material molding, involves the application of a second material over a pre-molded substrate. The influencing factors of the overmolding process include:

  1. Compatibility of materials: The compatibility of the substrate and overmolding materials is crucial to ensure proper adhesion and bonding. Material selection and compatibility testing are essential for a strong bond between the two materials.
  2. Material properties: The properties of both the substrate and overmolding materials, such as melt flow, shrinkage, and thermal characteristics, can influence the overmolding process. Matching the material properties helps to ensure proper flow, adhesion, and dimensional stability.
  3. Molding temperature: The temperature at which the overmolding process is performed affects the melt flow and adhesion between the two materials. Optimum temperature settings should be determined to achieve proper bonding without causing material degradation or distortion.
  4. Mold design: The mold design plays a significant role in overmolding. It should be designed to accommodate both the substrate and overmolding materials, allowing proper material flow, adhesion, and part ejection. The mold should also consider any undercuts, inserts, or complex geometries required for the final part.
  5. Injection parameters: The injection parameters, including injection speed, pressure, and time, should be for both the substrate and overmolding materials. Proper control of these parameters ensures good material flow, adhesion, and part quality.
  6. Surface preparation: Surface preparation of the substrate, such as cleaning, priming, or mechanical treatments, can improve adhesion between the substrate and overmolding material. Surface preparation methods should be selected based on the material compatibility and desired bond strength.
  7. Part design: The design of the part to be overmolded should consider factors such as draft angles, wall thickness, and part geometry to facilitate proper material flow, minimize stress concentrations, and achieve desired part quality.

These factors might vary depending on the specific overmolding process, materials used, and the desired properties of the final product.

A: Adhesion is a critical factor in the overmolding process because it directly influences the quality and performance of the final product. Successful adhesion ensures a strong bond between the substrate and overmolding material, leading to several benefits:

  1. Structural integrity: A strong bond between the substrate and overmolding material ensures structural integrity, preventing delamination or separation of the layers. This is especially important in applications where the part will be subjected to mechanical stresses or environmental conditions.
  2. Leak-proof sealing: Overmolding is often used to create seals or gaskets on a part. Proper adhesion ensures a tight and leak-proof seal, maintaining the integrity of the part and preventing any fluid or gas leakage.
  3. Improved aesthetics: Overmolding can be used to enhance the appearance of a part by applying a different color, texture, or surface finish. Strong adhesion ensures that the overmolding material adheres smoothly and uniformly to the substrate, resulting in an aesthetically pleasing finished product.
  4. Enhanced functionality: Overmolding can be used to introduce additional functionalities or properties to a part, such as adding soft-touch grips, anti-slip surfaces, or insulation. Strong adhesion ensures these additional features are securely attached to the substrate, providing the desired functionality.

To achieve successful adhesion in overmolding, it is essential to consider factors such as material compatibility, surface preparation, molding temperature, and injection parameters. Material selection should focus on finding compatible materials that have good adhesion properties. Surface preparation techniques, such as cleaning or priming, can improve adhesion by promoting bonding between the materials. Proper mold design and injection parameters should be chosen to facilitate good material flow and adhesion during the overmolding process.

Overall, successful adhesion in overmolding is crucial for ensuring the final product's durability, functionality, and aesthetic appeal.

A: There are several conditions to consider for successful overmolding. These conditions include:

  1. Material compatibility: The substrate and overmolding materials should be compatible to ensure proper adhesion and bonding. Compatibility can be determined through material selection and compatibility testing.
  2. Molding temperature: The temperature at which the overmolding process is performed is essential for achieving proper melt flow and adhesion between the materials. The molding temperature should be within the recommended range for both the substrate and overmolding materials.
  3. Injection parameters: Injection parameters, including injection speed, pressure, and time, should be optimized for both the substrate and overmolding materials. Proper control of these parameters ensures good material flow, adhesion, and part quality.
  4. Mold design: The mold design plays a crucial role in overmolding. It should be designed to accommodate both the substrate and overmolding materials, allowing proper material flow, adhesion, and part ejection. The mold should also consider any undercuts, inserts, or complex geometries required for the final part.
  5. Surface preparation: Surface preparation techniques may be necessary to enhance adhesion between the substrate and overmolding material. This can include cleaning, priming, or mechanical treatments to promote bonding between the materials.
  6. Part design: The design of the part to be overmolded should consider factors such as draft angles, wall thickness, and part geometry to facilitate proper material flow, minimize stress concentrations, and achieve desired part quality.
  7. Cooling and curing: After overmolding, proper cooling and curing processes may be required to ensure the materials solidify and bond effectively. This may involve cooling the part in the mold or subjecting it to post-molding curing processes.

It's important to note that these conditions may vary depending on the specific engineers to determine the specific conditions and parameters needed for a successful overmolding process.

A: Several common problems can occur in the overmolding process. These problems include:

  1. Poor adhesion: Insufficient adhesion between the substrate and overmolding material can result in delamination or separation of the layers. This can lead to part failure or reduced performance.
  2. Material incompatibility: Incompatible materials can result in poor adhesion, material cracking, or other issues. It's essential to ensure that the substrate and overmolding materials are compatible and have similar melt temperatures.
  3. Sink marks: Sink marks can occur when the overmolding material shrinks and pulls away from thicker substrate sections. This can result in visible depressions or marks on the part's surface.
  4. Warpage: Warpage can occur when there is uneven cooling or shrinkage between the substrate and overmolding material. This can result in a distorted or warped part shape.
  5. Flash refers to excess material that escapes from the mold during overmolding. It can occur at the parting line or other gaps in the mold. Flash can affect part dimensions, aesthetics, and functionality.
  6. Air traps or voids: Air traps or voids can occur when air gets trapped between the substrate and overmolding material during injection. These voids can lead to weak spots, reduced part integrity, or aesthetic issues.
  7. Overfill or underfill: Overfill refers to excessive material injected into the mold, while underfill occurs when insufficient material can fully cover the substrate. Both overfill and underfill can result in part defects and poor adhesion.
  8. Parting line mismatch: Parting line mismatch occurs when there is a mismatch between the two halves of the mold, resulting in misalignment or uneven parting lines. This can lead to poor aesthetics and compromised part integrity.

To address these common problems, it's essential to carefully consider and control factors such as material selection, mold design, injection parameters, cooling and curing processes, and surface preparation techniques. Conducting proper testing, validation, and troubleshooting can help identify and resolve these issues during the overmolding process.

A: When selecting resin materials for overmolding, there are several factors to consider. These factors include:

  1. Compatibility: The substrate and overmolding materials should be compatible to ensure good adhesion and bonding. It's essential to select materials that have similar melt temperatures and chemical properties to promote proper bonding between the layers.
  2. Melt flow and viscosity: The melt flow characteristics and viscosity of the overmolding material should be considered to ensure it can properly fill the mold and flow around the substrate. The material should have adequate flowability and low viscosity to achieve uniform coverage and minimize defects.
  3. Thermal properties: The thermal properties of the overmolding material are essential to ensure it can withstand processing temperatures and any subsequent service conditions. Consider factors such as melt temperature, heat resistance, and thermal expansion to ensure compatibility with the substrate and intended application.
  4. Mechanical properties: The mechanical properties of both the substrate and overmolding material should be considered to ensure the final part meets the desired performance requirements. Factors such as strength, flexibility, hardness, and impact resistance should be evaluated to ensure compatibility and desired part properties.
  5. Chemical resistance: Depending on the application, the overmolding material should be resistant to any chemicals, solvents, or environmental conditions it may come into contact with. Consider the compatibility of the material with potential substances or environments that could affect its performance or integrity.
  6. Aesthetics and surface finish: Consider the desired appearance and surface finish of the overmolded part. Some materials may provide better options for achieving specific textures, colors, or finishes. Consider the visual and tactile requirements of the final product.
  7. Cost and availability: The cost and availability of the overmolding materials should be considered to ensure they fit within the project budget and can be readily sourced. Evaluate the pricing, availability, and lead times for the selected materials.

It is essential to consult with material suppliers, conduct compatibility testing, and consider the application's specific requirements to make an informed decision when selecting resin materials for overmolding.

A: When designing an overmolding process, several precautions must be considered to ensure a successful outcome. Here are some essential precautions for overmolding process design:

  1. Material compatibility: Ensure that the substrate and overmolding materials are compatible regarding melt temperature, adhesion properties, and chemical compatibility. Incompatible materials can lead to poor adhesion, delamination, or other issues.
  2. Mold design: Design the mold to accommodate the overmolding process requirements. Consider factors such as proper gating, venting, and cooling to ensure uniform material flow, proper filling, and efficient cooling. Proper mold design can help prevent defects such as flash, sink marks, and warpages.
  3. Injection parameters: Optimize the injection parameters such as injection pressure, injection speed, and melt temperature to achieve proper material flow, fill the mold completely, and minimize defects. Carefully control these parameters to avoid overfilling or underfilling, which can lead to part defects or poor adhesion.
  4. Surface preparation: Properly prepare the substrate surface before overmolding. This may include cleaning, roughening, or applying a primer to enhance adhesion between the substrate and overmolding material. Good surface preparation is crucial for achieving strong bonding.
  5. Overmolding sequence: Consider the sequence in which the substrate and overmolding materials are injected into the mold. This can affect adhesion, material flow, and part quality. Determine the most suitable sequence based on material properties, mold design, and processing conditions.
  6. Cooling and curing: Properly cool and cure the overmolded part to ensure dimensional stability and minimize part defects. Adequate cooling and curing times should be determined based on the specific materials used and the desired properties of the final part.
  7. Quality control and testing: Implement quality control measures throughout the overmolding process. Conduct regular inspections, measurements, and testing to ensure the parts meet the required specifications. This may include checking for adhesion strength, dimensional accuracy, and overall part quality.
  8. Process validation: Validate the overmolding process through trial runs and testing before full-scale production. This helps identify and address any issues or adjustments needed to achieve consistent and reliable results.

Considering these precautions and paying attention to detail during the overmolding process design, you can increase the likelihood of achieving successful overmolded parts with good adhesion, dimensional accuracy, and overall quality.

A: While the overmolding process offers many advantages, there are also some potential disadvantages to consider. These include:

  1. Complexity: Overmolding can be a complex process, especially when different materials with varying properties are involved. This complexity may require additional equipment, expertise, and proper setup and optimization time.
  2. Material compatibility: Ensuring substrate and overmolding materials compatibility is crucial for successful bonding. If the materials are compatible, this may result in better adhesion, delamination, or other issues that affect the quality and performance of the part.
  3. Cost: Overmolding can be more expensive than traditional molding processes due to the additional materials, equipment, and setup. The cost of the overmolding materials and any required surface preparation treatments can also contribute to the overall cost.
  4. Design limitations: Overmolding may impose limitations on the part's design. The overmolding process requires consideration of factors such as material flow, mold design, and part ejection, which may restrict the design possibilities or require design modifications.
  5. Cycle time: Overmolding often has longer cycle times than traditional molding processes. The process may involve multiple injection steps, cooling, and curing times, which can extend the overall production time.
  6. Quality control challenges: Overmolding can introduce additional challenges in terms of quality control and inspection. Ensuring proper adhesion, identifying defects, and conducting quality checks on multiple layers can be more complex and time-consuming.
  7. Limited material options: Materials for overmolding may be limited compared to traditional molding processes. Material compatibility and adhesion requirements may restrict the available options, reducing the flexibility in material selection.
  8. Tooling and maintenance: Overmolding may require specialized tooling and molds, which can be more complex and expensive to manufacture and maintain. The tooling and molds need to be designed and maintained to accommodate the specific requirements of the overmolding process.

Despite these potential disadvantages, the overmolding process can still offer significant advantages in terms of improved aesthetics, enhanced functionality, and increased product durability. By carefully evaluating the specific application requirements and considering the potential challenges, manufacturers can effectively utilize overmolding to achieve their desired outcomes.

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