Every so often, a project comes along that reminds us why expertise and material choice matter so much—especially in the medical sector, where reliability is everything.
In medical manufacturing, small components can cause big problems if they don’t perform under pressure.
Recently, we were working with a medical device company based in mainland Europe on a moulded component for a critical device. They were developing a product that required a low pressure moulded part to seal and protect sensitive electronics. Like many projects in this field, the part had to meet strict performance standards, including a material that has robust adhesion and resistance to moisture, as well as a IP68 rating.
The Challenge
During the initial rounds of testing, the part failed two key requirements:
- Adhesion: The material wasn’t bonding effectively to the substrate.
- Water resistance: It could not withstand moisture exposure under the specified conditions.
The part had to pass strict regulatory testing, and these issues risked delaying production and certification.
What We Tried
Our team reviewed the design, substrate, and existing material choices. We tested a range of proven low pressure moulding (LPM) materials, including those that had performed well in previous projects. But none provided the combination of adhesion strength and water resistance required for this application. We needed to find a more tailored solution.
The Breakthrough: Technomelt PA653
After some testing and evaluation, we selected Henkel Technomelt PA653, a Polyamide-based hotmelt known for its strong adhesive properties and resilience in humid environments.
Switching to PA653 solved the problem:
- Adhesion tests: Secure and consistent across all critical contact points – The material sealed around the button without fault.
- Water resistance: The medical device now survived a 2-hour submersion under water without any water ingress.
With PA653, the component passed final validation, allowing the client to confidently proceed with production and certification.
The Bigger Picture
This project is a great example of how the right low pressure moulding (LPM) material can solve complex performance engineering problems. In applications where adhesion and environmental resistance are non-negotiable, Polyamide hotmelts like Technomelt PA653 stand out.
Polyamide-based materials, like Technomelt PA653, can meet a wide range of design and performance needs, offering:
- Encapsulation compatibility with delicate electronics
- Excellent adhesion to a wide range of substrates
- Moisture resistance for demanding environments
- Biocompatibility
- Customisation for industry-specific needs
And with the right expertise behind them, they can solve issues before they become problems.
Final Thoughts
In short: the right material, applied with the right process, can make all the difference.
It was a reminder that close collaboration and smart material selection are key to overcoming manufacturing roadblocks.
If you’re working on a project with demanding requirements, or stuck with a part that’s failing to meet them, we’d be happy to help you explore what’s possible with LPM hotmelts.
We work with a wide range of industries, providing low pressure overmoulding solutions, including:
- Medical: Overmoulding to meet the highest quality standards and reliability using the correct medical-grade plastic.
- Aerospace & Defence: Overmoulding to meet complex specifications, rigorous production processes and the highest levels of compliance.
- Automotive: Overmoulding of complex electric, electronic and non-electronic systems to deliver products with unwavering reliability.
- Environmental: Overmoulding to create products that need to withstand a variety of harsh conditions in many different environments.
- Electronics: Overmoulding of electronics to deliver effective IP rated packaging / enclosure, strain relief and cable sealing in one easy step.
- Lighting & Entertainment: Overmoulding to ensure powerful, user-friendly, robust products that perform consistently and reliably.
Whether you’re looking at ergonomic tools or electronic devices with improved functionality, contact us today to discuss low pressure moulding or product prototyping for your next project!
