Overmolding Printed Circuit Board Assemblies

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Printed circuit boards Assemblies (PCBA's) have been around since the early 1900's and have become common place in most electronic devices used today. PCBA's are designed and used in a wide array of applications because of their size and ability to work with peripheral devices.

Since PCBA's are so functional and dynamic they are integrated into many custom and unique assemblies. Given that PCBA's are sensitive to certain environments and not designed to be exposed to the elements some type of protective barrier is common. Two options that provide protection as well as aesthetics are done through an injection overmold process.

The first option is to overmold directly over the PCBA assembly. This option gives a more streamline appearance and can be customized with logos, custom colors and overall design of the overmold.

The second option is to provide a more protective barrier to the PCBA by encapsulating it with a Lexan encapsulation (cap). Lexan is a hard durometer resin that can withstand harsh applications. The cap is designed to house the PCB and provide a protective shell to any sensitive components. Once a cap is made; that can then be overmolded with the same options as the direct overmolding process allows

What is PCB Overmolding?

Overmolding in the context of PCBAs involves using injection molding to organize and safeguard the delicate components. There are generally two approaches to this. First, you can have the PCBA ready and inject the overmold material onto it. This direct approach offers flexibility, allowing for custom logos and design elements.

The second strategy takes protection up a notch. It employs what’s known as Lexan encapsulation—essentially a cap. This cap contains the PCB and shields its most sensitive parts. Once this protective cap is in place, over-molding proceeds as in the direct approach, ensuring both resilience and aesthetic appeal.

Enter PCB overmolding. This technique employs injection molding to encapsulate the PCBA in a robust shell. Consequently, the assembly gains added resilience and an improved appearance. Today, we’re examining this vital yet simple process.