In the push for smaller, tougher and more reliable electronic devices, one manufacturing technique is gaining quiet but widespread traction: Low Pressure Overmoulding (LPM). Unlike traditional injection moulding, LPM uses gentle processing conditions that make it ideal for encapsulating sensitive components, all while cutting costs and accelerating development.
What Makes Low Pressure Moulding Different?
While often confused with standard injection moulding, LPM operates at far lower pressures using specialised resins like hotmelts and polyamides. The result is a process that doesn’t just assemble parts — it protects them. This is a critical advantage for industries dealing with fragile PCBs, connectors, or embedded electronics.
Why Engineers Are Switching to Low Pressure Moulding?
- Low injection pressure = no damage to delicate electronics
- Aluminium or 3D-printed tooling slashes lead times and iteration costs
- Built-in sealing capabilities support high IP ratings and environmental resistance
- Faster than potting — with cleaner results and shorter TAKT times
- Ideal for low-to-mid volume production and rapid prototyping
- Supports complex builds with multi-shot or pick-and-place overmoulding
Design Considerations in Low Pressure Moulding
Good LPM outcomes start with good design. This includes choosing the right resin, accounting for the application environment, and planning the mould tool accordingly. Whether the goal is vibration dampening, waterproofing, or improved ergonomics, early-stage material selection and function-focused design are key.
LPM, Real-World Impact
At Overmould, we’ve seen LPM enable waterproof connectors in lighting systems, ruggedised medical devices and shock-protected electronics through low pressure silicone moulding (LPSM). These aren’t just performance upgrades, they’re changing capabilities that wouldn’t be feasible with conventional methods.
LPM is more than a process. For product developers, it offers a flexible, fast and cost-effective way to move from prototype to production without compromising the protection of critical electronics.
Are you exploring alternatives to potting or the optimum process for your product? Contact the Overmould team, we can help you assess whether LPM is right for your product.
