The product is manufactured as an integrated unit consisting of a conductive metal ring and medical-grade silicone. The metal base—typically made from medical-grade conductive materials such as stainless steel or titanium alloy—serves to transmit electrical signals. The solid silicone overmolding provides electrical insulation, flexible cushioning, and a waterproof seal. Precise conductive contact areas are left exposed to ensure stable contact between the electrode and the skin. The silicone and metal are bonded firmly together, preventing delamination or separation.
Utilizing an integrated compression-molding process, the metal ring and silicone are securely bonded, ensuring high structural integrity and resistance to delamination or cracking. The component features high dimensional precision with no visible gaps, offers excellent elasticity and tear resistance, and can be cleaned, disinfected, and reused.
The silicone material is non-cytotoxic and hypoallergenic; it can withstand standard medical sterilization methods, including high-temperature steam and ethylene oxide. The metal electrodes are corrosion-resistant with stable impedance, remaining resistant to oxidation even when exposed to sweat or disinfectants, thereby ensuring consistent electrical signal transmission over long-term use.
1.The seamless silicone overmolding on the metal component provides excellent electrical insulation, as well as water and dust resistance. It achieves a high sealing rating, effectively preventing electrical leakage and the ingress of bodily fluids that could otherwise corrode the metal. The design is highly durable, resisting cracking or delamination even after long-term, repeated use, which significantly lowers the costs associated with replacing equipment components.
2.The silicone material withstands temperatures ranging from -60°C to 310°C and offers resistance to both mechanical shock and ultraviolet (UV) radiation. The metal core provides superior electrical conductivity with consistent impedance. The integrated overmolded structure ensures that conductive elements remain securely in place—preventing loosening or shifting—and minimizes fluctuations in contact impedance.
3.With a soft, elastic feel, the silicone is resistant to extreme temperatures and immersion in medical-grade disinfectants. It does not yellow, become brittle, or leach harmful substances, even after repeated sterilization cycles, making it well-suited for the frequent disinfection protocols required in medical facilities.
Medical-grade solid silicone overmolded onto metal electrode rings is used in instruments for minimally invasive and surface-level medical diagnostics and treatments, home health monitoring devices, aesthetic and therapeutic equipment, and rehabilitation devices. Examples include home health monitors, radio-frequency (RF) skincare devices, and body-contouring therapeutic equipment; in these applications, the silicone-encased components serve as safe, conductive electrodes that balance user comfort with electrical safety.
Beyond medical electrode assemblies, the silicone overmolding process is widely utilized in sectors such as consumer electronics, smart wearables, new-energy vehicles, industrial equipment, and mother-and-baby care products. It allows for the overmolding of metal or plastic inserts to create components such as waterproof connectors, sensor seals, non-slip handles for equipment, protective covers for buttons, VR headset face masks, sealing components for EV charging guns, insulation and protective parts for power batteries, and grips for baby-care or maternal products.
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
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