‘Over moulding’ solves complicated assembly for garden product

OEM saves on assembly time, product failure and has a more aesthetically pleasing finish.

10th August 2017

Garden hose system needed rethinking

When designing a product for outdoors in the UK and wider afield, the temperature ranges, impact of sunlight and robustness of components all play key factors. When a market leading manufacturer approached Tex Plastics to help them solve some of their product quality issues, little did they realise it would also save them money.

Tex Plastics technical design team were challenged to do better!

The known issues of the current design were highlighted and the technical design team soon spotted another. The product was prone to failure as the polymer used became more brittle when left outdoors. The complex sub-assembly and ‘over moulding’ of the part were not questioned by the client. However, these were soon factored into the solution worked upon by Tex. 

The technical polymer was identified but then the real work began 

Understanding the degradation temperature variations and UV exposure has on the polymers used meant the selection of replacement polymer was relatively simple for the Tex design team. Their major focus was diverted to developing a better process for ‘over moulding’. Because this could enhance the products robustness and make sub assembly a much simpler process. 

A new ‘over moulding’ process was designed and the assembly costs plummeted 

The Tex design team recalculated the moulding process and developed a press side assembly system. This combined with specific features enabled them to facilitate crisp shut offs between steel and plastic, plastic and plastic and also die cast and plastic. This transformed the way the product needed assembling, dramatically reducing the handling whilst making the product much more robust. 

A better product, longer ‘in-use’ life and lower manufacturing cost per unit

The client was delighted with the outcome, they had solved their original quality issues and resolved others they were unaware of. With a little more expense invested in ‘front end design’ they were able to deliver a better product at a lower cost per unit.

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