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Our client is a long-established manufacturer specializing in crane remote control systems for industrial operations. In 2021, they designed a new generation of remote control devices built to withstand harsh working environments while meeting ergonomic and durability standards.
To support this development, they partnered with Alpine Mold for custom overmolded parts, including precise mold design, high-quality mold manufacturing, and overmolding injection molding of critical plastic housing components. Although the client provided full product designs and internal assembly references, Alpine Mold was responsible for verifying part compatibility, ensuring manufacturability, and achieving performance criteria.
Project Overview
The project involved five core crane remote control parts:
Top cover(overmoulded)
Overmolding layer (soft-touch TPE)
Cable clamp (injection moulded)
Base cover (injection moulded)
Clip(injection moulded)
Alpine Mold developed three sets of custom injection molds to produce five essential crane remote control parts, each designed to meet the structural and functional requirements of the overall assembly. For the top cover and overmolding layer, we provided complete overmolding services, utilizing PC+TPE materials and advanced molding over molding techniques. This ensured strong material bonding, a soft-touch surface, and seamless part integration.
Meanwhile, the cable clamp, base cover, and clip were manufactured using high-precision injection molding, with PC and PP materials chosen for their strength, stability, and cost-efficiency. All components—whether injection molded or custom overmolded parts—were engineered to meet IP66 waterproof standards, strict dimensional tolerances, and matte surface finish requirements. This guarantees both long-term performance and a professional appearance in harsh industrial environments.
Material Compatibility: PC+TPE
To ensure structural integrity and reliable bonding, our engineering team consulted material suppliers and confirmed compatibility between PC, TPE, and PP. This step was critical in achieving consistent quality and long-term durability for all custom overmolded parts used in the crane remote control system.
For this project, we used S136 stainless steel for molds requiring high wear resistance, corrosion resistance, and fine surface finishes. Its stability and polishability made it ideal for producing custom overmolded parts and injection parts of the crane remote control system, ensuring durability and strict appearance standards in harsh environments.
Challenge:
In the overmolding process, achieving strong adhesion between PC and TPE materials is critical to produce a durable and reliable remote controller shell. Without excellent bonding, the product’s structural integrity and performance could be compromised.
Solutions:
To overcome this challenge, we conducted rigorous testing, selected precise material formulations, and optimized the overmolding injection molding manufacturing process. By carefully controlling the overmolding process parameters and ensuring material compatibility, we successfully achieved strong adhesion between PC and TPE, resulting in high-quality custom overmolded parts.
Challenge:
Another challenge was to produce high-quality parts through overmolding injection molding that ensure the remote controller shell meets the stringent IP66 waterproof rating. This rating confirms the shell’s ability to resist water ingress and maintain reliable performance in wet and harsh industrial environments.
Solutions:
To meet the IP66 waterproof standard, we implemented rigorous waterproof testing and sealing measures throughout the overmolding process. Before official IP66 testing, we conducted thorough internal sealing inspections, carefully checking all sealing areas and interfaces of the custom overmolded parts for cracks, gaps, or leaks. During the IP66 test, our molding over molding products were fully submerged at a depth of 1 meter for 30 minutes, maintaining full operational integrity without any water intrusion or damage.
Challenge:
Ensuring precise fit and critical dimensions is essential for the assembly of overmolding injection molding products, especially to maintain the IP66 waterproof rating and reliable operation. Components such as the light guide, screw holes, and emergency stop button require exact tolerances to guarantee watertight seals and secure assembly.
Solutions:
Our quality control team conducted rigorous inspections of all critical dimensions and fit points:
Verified the light guide assembly fits tightly to ensure a watertight seal meeting IP66 standards.
Checked all holes to confirm screws pass through smoothly for easy and secure fastening.
Tested the emergency stop button assembly for secure fit to maintain IP66 waterproof integrity.
Ensured all parts fit together precisely, referencing detailed assembly files.
These strict quality control measures guaranteed that the final custom overmolded parts met both dimensional and functional requirements for dependable use in harsh industrial environments.
Why Choose Alpine Mold for Your Overmoulding Projects?
Extensive Experience: Over 20 years in plastic injection molding and custom overmolded parts manufacturing across diverse industries.
Expert Team: Skilled engineers and quality control professionals ensure every mold and product meets exacting standards.
Advanced Technology: Utilization of Mold Flow analysis, DFM optimization, Mold Design,Mold Making and state-of-the-art molding over molding techniques.
Customer-Centric Approach: Dedicated project management and fast response to customer needs ensure on-time delivery and smooth communication.
Comprehensive Services: From concept to production, we provide end-to-end overmolding services tailored to your unique product requirements.
Partner with Alpine Mold to bring your innovative plastic injection molding and overmolding injection molding projects to life with unmatched quality and reliability.
In this Crane Remote Control Parts Overmolding Services project, Alpine Mold provided a comprehensive solution covering precision mold design, tooling, and high-quality overmolding production. Our engineering team optimized material selection and applied advanced overmolding techniques with PC and TPE, ensuring strong adhesion, a comfortable soft-touch surface, and reliable long-term performance.
All components were designed and manufactured by Alpine Mold to meet IP66 waterproof protection, tight dimensional tolerances, and strict surface finish requirements. The result was a series of durable, custom overmolded parts that not only achieved aesthetic refinement but also delivered consistent performance in demanding industrial environments. The client was highly satisfied with the final parts, praising both the quality and reliability, and expressed willingness to continue future cooperation.
Looking for reliable overmolding services for electronic enclosures or industrial remote control parts? Contact Alpine Mold today to discuss your project requirements and receive a tailored solution.
