New TPE overmolded onto nylon on the cheap

An entirely new thermoplastics elastomer (TPE) formulation has been created for overmolding onto Nylon 6,6, offering better appearance, adhesion, and cost. Custom injection molding company Able American Plastics (Richmond, IL) utilized a new TPE from Star Thermoplastics Alloys & Rubbers Inc. (Broadview, IL), which, due to an improved formulation, costs Able American $0.70-$0.80 less per pound than the previous TPE used.

Star TPE alloy nylon overmolding

The Able American application overmolds TPE onto Nylon 6\6  to provide support and protect the corners of a large tool box. The cost savings added up for Able since each shot required a half a pound of TPE. Initially Star created a compound mixing its TPE with the elastomer Able had been using, seeing some improvement in adhesion. At one point, a mix that was 90% Star and 10% predecessor was applied, before Star created an entirely new compound.

Able has 10 Cincinnati Milacron injection molding machines ranging in size from 22 to 500 tons in a 20,000-sq-ft ISO 9001 certified facility. Star promotes its StarBond TPE alloys for overmolding applications. Reported qualities include: adhesion to a range of commodity and engineering plastics, heat resistance, and very clear and very soft grades.