Low pressure Molding could protect LED strip, PCB and magnetic very well. Macromelt & Technomelt as a common molding materials play in an encapsulating and environmentally protection on sensitive electronic components, IC molding sealing, Magnetic over molding and other sensitive components pakage. The main intention is to protect the sensitive electronic components during the molding stress, because high pressure molding would harm the properties of these components. Additionally, low pressure seal molding also protects electronic components against dust, moisture and vibration stress. It is also commonly used for Cable relief and sealing connectors.

1. 2 3
Mold Case
Encapsulate
Insert
Electronics
Overmold Test
Cure
Setting or
Vacuum
Test
Palletize
Insert
Electronics
Preheat
What is Macromelt Molding?
Macromelt Molding is a low pressure molding process with hotmelt adhesives. It can achieve superior sealing,
better protection of electrical/electronic components with higher productivity compared to those materials
widely used in current sealing processes e.g. 2-component casting/potting resins or silicones. This notable
process is environmentally compatible and contributes to total cost reduction due to improved productivity.
Process Flow Advantage of Macromelt Molding
Traditional Casting/Potting Process Flow
Macromelt Molding Process Flow
Low Injection Pressure
Encapsulates fragile/delicate components
• No damage to components
Improved Productivity
No chemical reaction: single-component material
• Simple and clean process
• Fast cycle times (10 - 50 seconds)
Superior Material Properties
Water-tight encapsulation with adhesion
• Excellent electric insulation and water resistance
Chemical resistance
• Depending on their chemical basis, the molding products
are resistant to gasoline, oils, alcohols, acids and alkalis
Excellent thermal durability characteristics
• Thermal cycle resistance, cold resistance, temperature
resistance (from -40°C to +150°C)
Based on non-toxic and renewable raw materials
• Environmentally compatible
Application Case -
Sensor: 2C Casting vs. Macromelt Molding
Current Technology
Low Pressure
Macromelt Molding
Adhesive
Consumption/unit
16g/unit (Casting)
4g/unit
(PA Hotmelt)
Cost of Adhesive/kg € X € 2X
Adhesive Cost/unit € Y € Y/2
Production Cycle/unit 2 hours 1 min
Production Space
Required
Occupies space for case
storage curing
No space for case
storage nor curing
Results after changing to Macromelt Molding:
• Adhesive cost saving = 50%
• Saving in production time
• Saving in production space
• Saving in component and energy costs
• Much better water-proof quality
Highlighted Features
Moldability
• Flexible and miniaturized product design
Low flammability
• UL94 V-0 available
Effective strain relief
400
350
300
250
200
150
100
50
0
0 200 400 600 800 1000 1200 1400
2-Component
Casting Resins
Macromelt
Molding
Process Time Hours - Days Seconds - Minutes
Machine
Maintenance
Every day Once a week
Total Cost Reduction
• Eliminates traditional housings and cases used in potting.
• Saves energy by eliminating the heat curing process.
• Uses less adhesive for PCB encapsulation.
• Mold made of aluminum helps to reduce cost.
Above data are taken from a real reference case
WhatisMacromeltMolding?
WhatisMacromeltMolding?
Injection Molding
Macromelt Molding
Injection temp: 180-240°C
Injection pressure: 5-40 bar
Injection pressure (bar)
Injectiontemperature(°C)

2. 4 5
Polyamide Polyolefin PAX Hotmelt
Product Macromelt®
OM Macromelt®
Q Macromelt®
OM730
Service Temp (°C) -40 to +150 -20 to +100 -20 to +150
inherently stable +200
Molding Temp (°C) +180 to +240 +180 to +200 +200 to +240
Viscosity range
( mPa.s )
1,000 to 7,000 5,000 to 15,000 ca. 2,000
Shore Hardness A80 to D50 A60 to A90 D42
Adhesion Properties Superior adhesion to
plastics e.g. ABS, PBT, PVC
Superior adhesion to PP,
PE, PET
passes reflow process
UL94 V-0 - -
Macromelt Molding Applications
Automotive Electronics
Macromelt molding can be applied to various automotive electronic systems and devices, such as tire pressure
monitoring systems (TPMS), PCBs for seat occupant sensors, belt lock sensors, ECUs for motorcycles, air quality
sensors, antennas for RF devices, smart entry (E-Key) systems, etc.
1. Water-tight connector
2. Micro-switch
3. Absolute angle sensor
4. Intelligent battery sensor
5. Air quality sensor
Connector potting
Hotmelts are used for sealing the plug and also for cable strain
relief.
Grommet injection molded in place
The molding process can be used to mold grommets in place.This
eliminates the time-consuming process of slipping the grommet
on, which can cause repetitive strain injury. The molding can also
include strain relief, which also enhances its esthetics.
Electronic component encapsulation
It is the low pressure applied during the molding process that
prevents damage to the sensitive electronic components and
elements. The molding protects the electronics from external
influences (moisture, mechanical stressing, etc.) and is capable
of serving as a housing.
Types of Macromelt Molding Materials
Three Main Application Groups of Macromelt Molding Products
MacromeltMoldingApplications
WhatisMacromeltMolding?
What is Macromelt Molding?
6. Temperature sensor

3. 6 7
8. Antenna coil
9. GND terminal
Mobile phone battery
Grommets / Sockets
Molded connectors / Sensors with water-tightness strain relief
Mobile Phone Applications
Macromelt molding can be applied to the mobile phone battery, antenna, strobe flash, and other delicate
components that require water-tightness, protection or encapsulation.
Automotive Electronics
MacromeltMoldingApplications
MacromeltMoldingApplications
7. Other kinds of sensors
Macromelt Molding Applications
PCB Overmolding

4. 8 9
Molding Machine Mold Set
The molding system consists of the molding product, the mold set, the machine, and the melting unit. The melting unit
for the hotmelt is usually used for injection of the hotmelt adhesive into the mold set at lower pressure compared to
conventional injection molding machines. The mold set, which is usually made from aluminum, facilitates the process
to trial stage as it is lower in cost compared to conventional ones.
Mold Set
Aluminum can be used as the material for making the mold set for Macromelt Molding due to
• Lower injection pressure of the process
• Better thermal conductivity of aluminum
• No abrasive ingredients, e.g. fillers, glass fibers, contained in hotmelt
Steel can also be used as the material for the mold set. If the component to be over-molded has steel or hard
glass filled components, it is recommended to have steel inserts in this area of the cavity.
Molding Machines
There are many types of molding machines available:
• For small-scale production with manually opened mold set.
• For production that needs higher productivity and output,
with a sliding stage or rotary table for the mold set.
Further details about molding machines are available from
our machine partners in each country.
System Solution
Henkel supports customers throughout project development, from initial sample-making with a trial mold set to
consultancy on designing complete packages for mass production based on long experience with this low pressure
molding technology.
MoldingMachineMoldSet
MoldingMachineMoldSet
Hotmelt Adhesives
Technical Support
Supply
Molding Product
Supply
System
Supply
Melting Unit
Molding Machines
Mold Sets
Melting Unit Supplier
Customer
Select right
hotmelt
• Check requirements
• Spot test, if required
• Develop new
product
• Trial with mold set
• Produce molded
samples for eval­uation
• Environmental
resistance
• Chemical resistance
• etc.
• Check requirements
• Decide right specifi-
cation
• Supply hotmelt and
machines
• Start production
Prototyping
Evaluation by
customer
Prepare
for production
Project
completion

5. 10 11
Casting Resins
1. Antenna coil 2. Connector and micro switch
3. Transformers
Casting Applications:
Henkel also offers casting resins based on epoxy and polyurethane. Their properties can be adjusted in many
ways by modifying their chemical compositions. They can be engineered to be very hard and impact-resistant
or soft and elastic. With low processing viscosity, they can fill even the smallest gaps.
Technical Information
Casting Resins General Overview
Product CR 8101 CR 3127 CR 3311 CR 5441 CR 6127
Hardener UK 5400 CR 4300 UK 5600 CR 4300 CR 4300
Mixing ratio (weight) 4:1 5:1 100:25 100:45 85:15
Properties
Color Light brown Light brown Colorless Light brown white black
Viscosity
at 20°C mixed (mPa.s)
2650 3400 3200 1000 2400
Potlife at 20°C (min) 60 90 30 25 2-15-90
Shore hardness D 35 - 45 D 60 - 70 000 40 D 50 - 60 A 84
Flammability UL94 - V-0 - - V-0
for Electronic Electrical Applications
Technical Information
Product Range for Macromelt Molding
Polyamide General Overview
Product
Test
Method
OM652
OM657
6208
6208S
OM633
OM638
OM641
OM646
OM673
OM678
OM648 OM730
Properties
Color -
Amber
Black
Amber
Black
Amber
Black
Amber
Black
Amber
Black
Black Amber
Service Temp
Range (°C)
-
-40 to
+100
-40 to
+100
-40 to
+130
-40 to
+130
-40 to
+140
-40 to
+130
-20 to
+150
Softening Point
(°C)
ASTM E28 +155 +155 +175 +175 +185 +175 +200
after curing
Viscosity at
+210°C (mPa.s)
ASTM D3236 4,000 3,000 3,500 7,000 3,000 7,300 ca. 2,000
Shore Hardness ISO 868/15s A77 A82 A90 A92 A90 A93 D42
Creep Resistance
(°C)
Henkel
Method MH11
+125 +130 +155 +155 +130 +155 +200
Cold Flexibility
(°C)
ASTM D3111 -50 -40 -30 -35 -40 -30 -15
Flammability
UL94 File
E182771
V-0 V-0 V-0 V-0 V-0 - -
Low temp. storage
(°C)
Henkel
Method MH40
-40
1000h
Special Properties
Good cold
flexibility
RTI value
for 6208S:
95°C
UV
stabilized
Moisture
curable
Adhesion Properties
Substrate
PA6.6 Good Good Moderate Moderate Moderate Moderate Moderate
PVC Good Good Good Excellent Good Moderate Good
ABS Good Good Moderate Moderate Moderate Moderate Moderate
Macromelt products are thermoplastic hotmelt adhesives based on natural fatty acids. They show good adhesion to
plastics like PA 6.6,ABS and PVC, low temperature flexibility, a wide service temperature range, and superior molding
properties.
CastingResins
The data above is based on our knowledge and experience. Due to different materials and conditions of application which are beyond our knowledge and control we strongly
recommend carrying out sufficient tests and consulting of our technical customer service. Except for willful acts any liability based on such recommendations or any oral advice
is hereby expressly excluded.
A variety of adhesive values – spot tests, peel strength, shear strength – are available on request or can be supplied after testing by our technical customer service team.
Electrical Properties:
Volume Resistivity DIN IEC 60093 ~ 1012
Ω cm
Dielectric Strength DIN IEC 60243-1 ~ 20 kV/mm
The electrical values of OM648 and OM720 are not available.
TechnicalInformation
The data above is based on our knowledge and experience. Due to different materials and conditions of application which are beyond our knowledge and
control we strongly recommend carrying out sufficient tests and consulting of our technical customer service. Except for willful acts any liability based on such
recommendations or any oral advice is hereby expressly excluded.

6. QL-CUSTOM TECHNOLOGY LTD
Your Low Pressure Molding Supplier
https://www.ql-custom.com/lpm.html
Cable assembly and Wire Harness
https://www.ql-custom.com/cableassy.html