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Home Xometry Community Manufacturing Ergonomic Hand Tool Handle: Overmolding or Something Else?

Ergonomic Hand Tool Handle: Overmolding or Something Else?

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Hello everyone, I am in the early stages of developing a new hand tool (wire cutter). The tool needs an ergonomic handle that provides a good grip and comfort even during prolonged use. I am considering various materials, including plastics and metals, and am thinking about overmolding the handle with an elastomer to ensure additional comfort and slip-resistant properties. However, I have almost no experience with overmolding. Can anyone help me or provide insight into potential problems if I decide for overmolding? Or if I decide for a pure plastic part, could SLS/MJF PA12 be suitable for such a handle? Any advice on materials, manufacturing processes, or design tips would be very helpful! Thank you very much! Max

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      Hello everyone, I am in the early stages of developing a new hand tool (wire cutter). The tool needs an ergonomic handle that provides a good grip and comfort even during prolonged use. I am considering various materials, including plastics and metals, and am thinking about overmolding the handle with an elastomer to ensure additional comfort and slip-resistant properties. However, I have almost no experience with overmolding. Can anyone help me or provide insight into potential problems if I decide for overmolding? Or if I decide for a pure plastic part, could SLS/MJF PA12 be suitable for such a handle? Any advice on materials, manufacturing processes, or design tips would be very helpful! Thank you very much! Max
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    • Xometry Engineer

      Hi Max, thanks for your question. We can print in Polyjet hard – soft. The connection here is not always optimal. This would be the solution from one print. I don’t know if you could print in 2 parts, i.e. the handle made of soft material such as TPU over the second, hard one? PA 12 in SLS/Mjf I think is always a good choice and certainly provides a first statement about ergonomics.

      VG

      Niko

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        Nikolaus Mroncz

        Hello Niko,

        Thank you very much for the information. Would Polyjet or the TPU solution be durable enough for a final product? I would need some prototypes for testing, but for the final product I thought it would make sense to work with hard plastics or rubber/elastomer for durability reasons.

        Do you know if overmoulding is a cost-effective solution?

        Otherwise, I think it’s possible to have two components for the handle.

        Thanks,

        Max

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    • Xometry Engineer
      Maximilian Lang

      Hey Max,

      which process is best for you also strongly depends on the design and quantity of your parts.

      Unfortunately, I can only recommend the Polyjet for prototype manufacturing, as hard and soft components do not have the best adhesion and are only short-term when used. I would try the TPU version.

      Overmolding would be an option, one would need to compare accordingly, which is more economical.

      Best regards

      Niko

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      Nikolaus Mroncz

      All clear, thank you!

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Ergonomic Hand Tool Handle: Overmolding or Something Else?
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