What Overmolding Can Do for Wearable Technology

Cavist Wearable Electronics VR

The Ascension of Wearable Electronics​

The rise of wearable technology has significantly transformed the daily lives of many by embedding advanced electronics into accessories that people use and wear every day. From tracking fitness to enhancing interaction with the digital world, wearable electronics have become indispensable. The most popular types of wearables include fitness trackers, smartwatches, medical devices, and augmented reality (AR) glasses. These devices not only offer convenience and health insights but also push the boundaries of personal technology integration.

However, the widespread adoption of wearable technology comes with challenges, particularly concerning durability and protection against various environmental conditions. Wearable devices need to withstand moisture, dust, shock, and other potential hazards to ensure longevity and reliable performance. Cavist strives to be an expert source for premium protection for such devices under these conditions.

cavist wearable waterproof electronics
Wearable Waterproof Applications

Overmolding as a Protective Solution

Overmolding has emerged as a robust solution to enhance the durability and protection of wearable electronics. This manufacturing process involves molding over an electronic board using a variety of materials, forming a protective outer layer. This can be either a 1-Shot or 2-Shot process. A specialized overmolding technique, Low Pressure Molding (LPM), is particularly beneficial for electronics. Unlike traditional molding processes, LPM uses lower injection pressures and temperatures, which is crucial for delicate electronic components. Without proper care for these small devices, higher pressure techniques can cause damage and malfunctions. Take a look at our 2-Shot Overmolding process for wearables.

The process of low pressure overmolding offers several advantages

Overmolding provides excellent resistance to moisture, dust, and mechanical shocks, crucial for wearable electronics exposed to different environmental conditions. The additional protective layer significantly extends the lifespan of the devices by safeguarding their internal components. Skipping past overmolding can significantly reduce the length that these devices can be fully functional. Cavist’s molding process can achieve IP68 ingress protection for its devices, making sure that your product can withstand any test.

With overmolding as thin as 1mm, the weight of Cavist’s protection when compared to other methods of encapsulation is significantly less. When the device is wearable, the feel of the device is paramount, so reductions in heft are greatly appreciated.

The lower pressure and temperature reduce the risk of damage to sensitive electronics during the molding process. The gentle process minimizes the stress on components, enhancing their reliability and performance.

Cavist’s scalable manufacturing process allows for large LPM output while remaining cost effective for its customers. Our satisfied clients have ordered large outputs that we can successfully manage.

Cavist Wearable Medical Electronics
Wearable Medical Applications

Applications in Wearable Technology

Fitness Trackers and Smartwatches

These devices are often exposed to sweat, water, and varying physical conditions. Overmolding provides the necessary protection, ensuring that they remain functional and reliable during rigorous physical activities.

Medical Monitoring Devices

Reliability is paramount for medical devices that monitor vital health parameters. Overmolding safeguards these sensitive electronics, ensuring accurate and consistent performance, which is critical for patient health.

Augmented Reality Glasses

AR glasses integrate complex electronic and optical components. Overmolding protects these delicate parts from dust, moisture, and mechanical shocks, ensuring a seamless user experience and device longevity.

Law Enforcement Devices

In the high-pressure environment of policing, having reliable cameras to document occurrences is pivotal. Cavist has specifically worked with these equipment manufacturers on overmolding these wearable devices.

Cavist Wearable Fitness Electronics
Wearable Fitness Applications

Looking Forward

The future of wearable technology hinges on ensuring the durability and reliability of these sophisticated devices. Overmolding, particularly techniques like Low Pressure Molding, plays a pivotal role in this aspect by providing superior protection and enhancing the user experience. As wearable electronics continue to evolve, the importance of overmolding in their development will only increase, driving innovation and expanding the possibilities of personal technology.

The integration of overmolding in the manufacturing of wearable electronics not only addresses the critical challenge of durability but also opens new avenues for innovation, making these devices more resilient and user-friendly. As we move forward, the synergy between advanced protective solutions and wearable technology will shape the future landscape of personal electronics.


Take the next step

Reach out to Cavist to get more information about low pressure molding, wearable applications, and anything in between. We would be happy to help you design a protective solution for your device!