This product features a design where a metal vape body is encapsulated in liquid silicone, specifically covering the main body and the grip area. To prevent issues such as air bubbles, delamination, or uneven silicone distribution during the encapsulation process, Dongcheng’s engineers moved away from traditional methods in favor of liquid silicone injection molding. This approach ensures high production efficiency and excellent product consistency.
The process utilizes an integrated liquid silicone injection molding technique involving two components (Component A and Component B). A metering system maintains a precise 1:1 ratio, and a static mixer ensures thorough blending. The mixture is then injected via a screw into a heated mold, where the silicone cures at temperatures ranging from 120°C to 200°C. Injecting liquid silicone into a hot-runner mold enables single-step forming, resulting in zero waste and suitability for automated production.
The outer liquid silicone layer is safe and eco-friendly, meeting food-grade and RoHS standards; it offers resistance to extreme temperatures and is highly durable against yellowing and aging. The inner metal core provides structural rigidity and deformation resistance. The complementary strengths of these two materials allow for customization of silicone hardness and surface finishes—such as frosted or matte textures—enhancing both the product's appearance and tactile feel.
1.Following injection molding, the liquid silicone bonds tightly to the metal substrate, eliminating parting lines and assembly gaps; this ensures excellent water and sweat resistance—meeting the IP68 standard—and effectively protects internal electronic components. The overmolded layer resists delamination and peeling, resulting in a longer service life.
2.Liquid silicone offers a smooth, skin-friendly feel while complementing the rigidity of the metal; its elastic nature absorbs impact from drops, resists scratches and wear, and provides superior slip resistance. Additionally, the material is resistant to aging, ensuring it does not harden or become brittle over time.
3.With excellent flowability and high molding precision, liquid silicone allows for the integrated molding of complex curves and intricate textures. Colors, logos, and overmolding areas can be fully customized. The process reduces the need for manual trimming, ensures consistent quality in mass production, and achieves higher yield rates.
Shenzhen ES Electronic Co., Ltd.’s liquid silicone overmolding process is suitable for the bodies of various portable vape devices and for the customization of handheld accessories for high-end consumer electronics.
As a high-value-added composite manufacturing technique, the company’s silicone-over-metal process is widely applied across the automotive, medical, and electronics sectors—producing precision components such as waterproof sensors, non-slip handles, and metal knobs or buttons for controllers.
1.Fully Customized Products: All ES Silicone products are custom-made based on customer requirements.
2.MOQ Requirements: MOQ varies by product category, structure, and production requirements. Typically, orders start from 100 pieces.
3.Prototype & Mass Production: We support prototype validation before mass production. Reasonable prototype fees apply and may be credited for qualified projects.
4.Engineering Support: Our engineering team provides DFM evaluation to optimize product feasibility and ensure stable production.
5.More Project Cases: Website examples represent selected non-confidential projects. Contact us for more customized applications and solutions.
6.Learn More About ES Silicone: Discover our capabilities and workflow through Who We Are and How We Work.
Keypads & Buttons
Protective Covers
LSR Overmolding
Seals & Gaskets
Conductive Zebra Strips
Other Silicone Components
Financial & Payment
Consumer Electronics
Industrial Control
Beauty & Personal Care
Medical & Healthcare
Others