OVERMOULDING

As an Automotive and Military Harness Manufacturer we recognise

the importance of water ingress prevention by overmoulding connections

Water ingress and mechanical wear and tear degrades electrical systems. To this end, Brucom has invested heavily in overmould technology.

 

With in-house tooling facilities, overmoulding machines are used to quickly design, manufacture and overmould any connector, PCB or component to the customer’s requirements within weeks from inception to delivery. 

 

With in-house 3D printing facilities, we can design and recreate the required model in a matter of hours.

Our in-house tooling facilities can design manufacture and present solutions in as little as 2-3 days, with production tooling lead times ranging from 2 – 12 weeks depending upon complexity.

Brucom overmoulds in excess of 250,000 moulds per year and is steadily increasing year on year.

Building on our success of the Tyco Superseal range of over moulded cable assemblies,  Brucom has 4 new ranges of overmoulded connector systems to offer. These include a range of accessories such as T-Pieces, Y-Pieces, Manifolds and Junctions along with the cable assemblies.

  • Deutsch DT Range

  • Mizu P25 Range

  • Din 72585

  • HDSCS.

Brucom utilises the injection moulding process for many different applications such as:

  • Connectors

  • PCB’s

  • Grommets

  • Switch panels

  • Junction blocks

  • Gaskets

  • Sensor encapsulation (door sensors)

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The Deutsch connector is one of the most widely used connectors in the agricultural and plant industry. The DT series has similar properties to the super seal range, however with a wide portfolio of cavities, it can be used from 2 - 12 circuits all rated at 13 Amps.

 

These connectors offer field proven reliability and rugged quality. You have the ability to use multiple size 16 contacts, each with 13 Amp continuous capacity, within a single shell. 

 

Our new overmould range complements this impressive connector to allow take offs, joiners, 90 degree outlets and splitters. The splitters can also be configured to either share a function or have independent functions at each take off.

 

Further moulds will be added to this line in the near future to extend the

array of possible configuration options.

DEUTSCH

1/2 - 1/3 OVERMOULDED CONFIGURATIONS

Material Specifications:

  • Grommet: Silicone rubber

  • Insert Retainer: Thermoplastic

  • Receptacle Interfacial Seal: Silicone rubber

  • Shell: Thermoplastic

  • Wedgelocks: Thermoplastic

  • Casing: Overmold

 

THE MOST RELIABLE AND ROBUST SYSTEM YOU CAN ADD TO YOUR TRAILER BUILDS

JUNCTION BLOCK

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QUICKLY AND NEATLY MOUNT THIS JUNCTION BLOCK TO THE VEHICLE,

THEN SIMPLY ATTACH ALL VEHICLE FUNCTIONS IN ONE LOCATION.

BLOCKS ARE BRANDED WITH YOUR COMPANY NAME / LOGO ALONG WITH LABELLED FUNCTIONS FOR EASY INSTALLATION.

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MACHINERY

Our latest overmoulding machine is the Mold-Man 6200. The low pressure, single action overmolding machine offers simple versatility, with the addition of a shuttle table. This allows a significant increase in the number of parts that can be produced per hour.

Features

  • No heated hose, exposed heated joints or exposed moving injector nozzles.

  • Precision flow and metering system via the gear pump and air pressure, allowing for shot weights to be injected as fast or slowly as the moulding requires.

  • Open frame design for easy access to the mould tool and injection point.

  • Light curtain and safety actuation.

  • 2T clamping force.

  • Intuitive touch screen operation.

  • Shuttle table.

  • Quick Exchange melt reservoirs.

  • Simple injection via patented system

Technomelt

The Technomelt material used in our process is a high-performance thermoplastic polyamide designed specifically for low-pressure molding processes, this protects the substrate and components from damage, the general specification is shown below:

  • Automotive standards operating temperature -40 to +105oC

  • Resistant to diesels and oils.

  • UL 94 V0 flammability rating

  • 77 shore hardness

  • 400% elongation to break

  • 15 Kv/mm Dielectric strength

  • Electrical Resistance to IPC-TM-650 accredited

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HAVE ANY QUESTIONS?

Brucom's technical sales team is at hand to discuss your requirements.

Call: 01889 272645

HOW CAN BRUCOM HELP YOU?

We can help in many ways, here are just a few key services to go along with your overmoulds.

 

  • Low-cost manufacturing

  • Custom overmoulds

  • 100% inspection