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Si-TPV Overmolding of Tool Handles Redefines Ergonomics Boosting Safety and Comfort

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In the process of designing handles for both powered and non-powered tools, SILIKE’s Si-TPV series dynamic vulcanizate thermoplastic silicone-based elastomers serve as a comprehensive solution for improving ergonomics. By combining the advantages of silicone rubber and thermoplastic elastomers, Si-TPV provides a lightweight, durable, and comfortable soft-touch surface that enhances grip and reduces vibration. The over-molding capability of Si-TPV Eco-Friendly Soft Touch Material materials allows manufacturers to craft sturdy, flexible, and visually appealing handles that greatly increase user comfort and safety. Furthermore, Si-TPV’s resistance to wear, oil, and grease ensures prolonged performance, making it a cost-effective option for power tools used in challenging environments.

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Detail

SILIKE's Si-TPV series products address the challenge of incompatibility between thermoplastic resin and silicone rubber through advanced compatibility and dynamic vulcanization technologies. This innovative process disperses fully vulcanized silicone rubber particles (1-3µm) uniformly within the thermoplastic resin, creating a unique sea-island structure. In this structure, the thermoplastic resin forms the continuous phase, while the silicone rubber acts as the dispersed phase, combining the best properties of both materials.
SILIKE's Si-TPV series Thermoplastic Vulcanizate Elastomers offers a soft touch and skin-friendly experience, making them the ideal choice for overmolding on handles for both powered and non-powered tools, as well as handheld products. As an innovative over molding solutions material, Si-TPV softness and flexibility of Elastomers are designed to provide a soft feel and/or non-slip grip surface, enhancing product features and performance. These slip Tacky Texture non-sticky elastomeric materials enable handle grip designs that combine safety, aesthetics, functionality, ergonomics, and eco-friendliness.
The Si-TPV series soft over-molded material also exhibits excellent bonding with a variety of substrates, including PP, PE, PC, ABS, PC/ABS, PA6, and similar polar substrates or metals. This strong adhesion ensures durability, making Si-TPV an ideal choice for producing long-lasting, soft and comfortable handles, grips and button.

Key Benefits

  • 01
    Long-term soft skin-friendly comfort touch does not require additional processing or coating steps.

    Long-term soft skin-friendly comfort touch does not require additional processing or coating steps.

  • 02
    Stain-resistant, resistant to dust accumulated, resistant against sweat and sebum, retaining the aesthetic appeal.

    Stain-resistant, resistant to dust accumulated, resistant against sweat and sebum, retaining the aesthetic appeal.

  • 03
    Further surface durable scratch & abrasion resistance, waterproof, resistance to weather, UV light, and chemicals.

    Further surface durable scratch & abrasion resistance, waterproof, resistance to weather, UV light, and chemicals.

  • 04
    Further surface durable scratch & abrasion resistance, waterproof, resistance to weather, UV light, and chemicals.

    Further surface durable scratch & abrasion resistance, waterproof, resistance to weather, UV light, and chemicals.

  • 05
     Si-TPV creates a superior bond with the substrate, it is not easy to peel off.

     Si-TPV creates a superior bond with the substrate, it is not easy to peel off.

Durability Sustainability

  • Advanced solvent-free technology, without plasticizer, no softening oil, and odorless.
  • Environmental protection and recyclability.
  • Available in regulatory-compliant formulations

Si-TPV Overmolding Solutions

Overmolding recommendations

Substrate Material

Overmold Grades

Typical

Applications

Polypropylene (PP)

Si-TPV 2150 Series

Sport Grips, Leisure Handles,Wearable Devices Knobs Personal Care- Toothbrushes, Razors, Pens, Power & Hand Tool Handles, Grips, Caster Wheels,Toys

Polyethylene (PE)

Si-TPV3420 Series

Gym Gear, Eyewear, Toothbrush Handles,Cosmetic Packaging

Polycarbonate (PC)

Si-TPV3100 Series

Sporting Goods, Wearable Wristbands,  Handheld Electronics, Business Equipment Housings, Healthcare Devices, Hand and Power Tools, Telecommunications and Business Machines

Acrylonitrile Butadiene Styrene (ABS)

Si-TPV2250 Series

Sports & Leisure equipment, Wearable Devices, Housewares, Toys, Portable Electronics, Grips, Handles, Knobs

PC/ABS

Si-TPV3525 Series

Sports Gear, Outdoor Equipment,Housewares, Toys, Portable Electronics, Grips, Handles, Knobs, Hand and Power Tools, Telecommunications and Business Machines

Standard and Modified Nylon 6, Nylon 6/6, Nylon 6,6,6 PA

Si-TPV3520 Series

Fitness Goods, Protective Gear, Outdoor Hiking  Trekking Equipments, Eyewear, Toothbrush Handles, Hardware, Lawn and Garden Tools, Power Tools

Overmolding Techniques & Adhesion Requirements

SILIKE Si-TPV (Dynamic Vulcanizate Thermoplastic Silicone-based Elastomer) Series products can adhere to other materials through injection molding. Suitable for insert molding and or multiple material molding. Multiple material molding is otherwise known as Multi-shot injection molding, Two-Shot Molding, or 2K molding.

Si-TPV series have excellent adhesion to a variety of thermoplastics, from polypropylene and polyethylene to all kinds of engineering plastics.
When selecting a Si-TPV for soft touch overmolding application, the substrate type should be considered. Not all Si-TPVs will bond to all types of substrates.

For more information regarding specific Si-TPV overmolding and their corresponding substrate materials, please feel contact us now to learn more or request a sample to see the difference Si-TPVs can make for your brand.

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Application

SILIKE Si-TPV (Dynamic Vulcanizate Thermoplastic Silicone-based Elastomer) Series products offer a uniquely silky and skin-friendly touch, with hardness ranging from Shore A 25 to 90. For manufacturers of hand and power tools, as well as handheld products, achieving exceptional ergonomics, safety, comfort, and durability is crucial. SILIKE’s Si-TPV overmolded lightweight material is an innovative solution designed to meet these needs. Its versatility makes it ideal for a range of grip handles and button parts, end products including hand and power tools, cordless power tools, drills, hammer drills, impact drivers, grinders, metalworking tools, hammers, measuring and layout tools, oscillating multi-tools, saws, dust extraction and collection, and sweeping robot.

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Solution:

Si-TPV Overmolding for Power and Hand Tools, What You Need To Know

Understanding Power Tools and Their Applications

Power tools are indispensable across industries such as construction, aerospace, automotive, shipbuilding, and energy, and they are also commonly used by homeowners for various tasks.

The Power Tools Challenge: Ergonomic design for comfort and safety

Similar to traditional hand tools and handheld devices, manufacturers of power tools face the significant challenge of creating handle grips that are tailored to meet the ergonomic requirements of the operators. The misuse of electrically powered portable tools has the potential to result in severe and excruciating injuries. With the development of cordless tools, The introduction of battery components in cordless tools has led to an increase in their overall weight, thereby posing additional complexities in the design of ergonomic features.

When manipulating the tool with their hand—whether through pushing, pulling, or twisting—the user is required to exert a specific degree of grip strength to ensure safe operation. This action can directly impose mechanical loads on the hand and its tissues, potentially leading to discomfort or injury. Furthermore, as each user applies their own preferred level of grip strength, the development of ergonomic design that places utmost importance on safety and comfort becomes crucial.

Way to Overcoming Ergonomic Design Challenges in Power Tools

To overcome these design-related challenges manufacturers need to focus more on the ergonomic design and comfort of a user. Ergonomically designed power tools provide better comfort and control to the operator, allowing the work to be completed with ease and less fatigue. Such tools also prevent and reduce the health problems associated with or caused by using specific power tools. Besides, features such as vibration reduction and non-slip grips, balancing tools for heavier machines, lightweight housings, and extra handles help enhance user comfort and efficiency while using the power tools.

However, productivity and efficiency are strongly influenced by the level of comfort or discomfort experienced during the use of power tools and hand products. Therefore, designers need to enhance the interaction between humans and products in terms of comfort. This can be achieved by improving the functionality of the tools and products, as well as by enhancing the physical interaction between the user and the product. Improvements in physical interaction can be made through the size and shape of gripping surfaces and the materials used. Research indicates a strong correlation between the mechanical properties of materials and the user’s subjective psychophysical response.  Additionally, some findings suggest that the material of the handle has a greater influence on comfort ratings than the handle’s size and shape.

  • Si-TPV power tools handle material for improved ergonomics (2)

    Are you facing hand grip material Challenges? SILIKE offers the Solution.
    SILIKE developing a variety of Si-TPV elastomers is a versatile material that has the properties of both silicone rubber and thermoplastic elastomer, It is lightweight, durable, and resistant to wear and tear, making it an ideal choice for many applications. to serve sporting &leisure equipment, personal care, power &hand tools, lawn and garden tools, toys, eyewear, cosmetic packaging, healthcare devices, smart wearable devices, portable electronics, hand-held electronics, household, and other appliances markets, with a long-lasting comfortable soft touch feel, and stain resistance, these grades meet application-specific needs for aesthetics, safety, antimicrobial and grippy technologies, highly resistant to chemicals.
    Innovation Si-TPV Overmolding in Hand and power tools
    Overmolding is a great solution, especially in power tools devices — is a product that’s easy to use and withstands impact, abrasions, chemical reactions, and changes in temperature and humidity, it perfectly meets a critical need for the use of handheld. Plus, Over-molding allows manufacturers to create Ergonomically products that are both strong, durable, flexible, and lightweight. This process involves combining two or more materials to create a single, unified product. compared to traditional methods of joining two parts together. manufacturers are able to reduce costs associated with production and assembly. As well as, can be used to create products with unique shapes and designs.

  • Si-TPV power tools handle material for improved ergonomics (1)

    As an overmolding material, Si-TPV Plasticizer-free thermoplastic elastomers can bond with the substrate that endures the end-use environment. It can provide a soft feel and/or non-slip grip surface for improved product features or performance.
    When using Si-TPV Skin-Friendly Soft Overmolding Materials the design and development of handles for powered and non-powered tools and handheld products, not just appears to simply enhance the aesthetically pleasing of a device, adding a contrasting color or texture. Especially, Si-TPV overmolding’s lightweight functionality also elevates ergonomics, deadens vibration, and improves a device’s grip and feel. By this means the comfort rating is also increased compared to stiff handle interface materials such as plastic. As well as to provides additional protection from wear and tear which makes it an ideal solution for power tools that need to withstand heavy use and abuse in a variety of environments.
    Si-TPV Thermoplastic Silicone Elastomers also have excellent resistance to oil and grease which helps keep the tool clean and functioning properly over time.
    Additionally, Si-TPV Safe Sustainable Soft Alternative Material is more cost-effective than traditional material, allowing manufacturers to produce more products in less time. It is an attractive option to create custom products that meet their specific needs while still providing superior performance in a variety of applications.

  • Sustainable-and-Innovative-218

    Struggling with the Ergonomics, Safety, Comfort, and Durability of Your Hand and Power Tools?

    This Si-TPV soft over-molded material helps you with handles for both powered and non-powered tools, as well as handheld product issues/pain points.

    Most designers and product engineers agree that overmolding offers greater design functionality compared to traditional “one-shot” injection molding, resulting in components that are both durable and pleasant to the touch.

    While power tool handles are often over-molded using silicone or TPE, if you’re looking to set your product apart with handles that combine aesthetics, durability, and ergonomic design, SILIKE’s Si-TPV overmolding is the sustainable alternative. These Soft-Touch Thermoplastic Elastomers materials are driving design innovation in the power tools industry.

    Don’t miss out on the benefits of Si-TPV overmolding Eco-friendly soft touch material.

    For more information, please contact Amy Wang at amy.wang@silike.cn.

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