TPE-Avient GLS Versaflex OM 1040X
Achieving an unbreakable chemical bond over rigid polar engineering plastics like PC, ABS, and PC/ABS alloys without secondary adhesives requires specialized interface chemistry, which Avient’s Versaflex OM 1040X-1 delivers through its medical-compliant, elastomer-modified TPS matrix. Boasting a density of 0.920 g/cm³ and an ultra-soft hardness of 42 Shore A, this translucent overmolding grade complies with ISO 10993 and USP Class VI biocompatibility regulations. Jucheng Precision, under strict ISO 13485 and ISO 9001 certified medical contract manufacturing systems, specializes in multi-shot overmolding of Versaflex OM 1040X. Utilizing 5-axis CNC-machined tooling, we optimize gating and manage its high shrinkage (2.0%-2.6%) to secure peeling-free aesthetic interfaces verified by Zeiss CMM.
Versaflex OM 1040X Mechanical Integrity & Medical Compliance
Versaflex™ OM 1040X-1 is an unreinforced, translucent thermoplastic elastomer (TPE) compound engineered by Avient, certified to deliver outstanding overmolding adhesion and biological safety under MedTech standards:
| Physical & Compliance Property | Versaflex OM 1040X Spec Metric | Medical Overmolding Advantage |
|---|---|---|
| Polar Base Adhesion | Outstanding Chemical Bonding | Achieves a permanent, weld-free molecular bond with polar rigid polymers (PC, ABS, PC/ABS) during multi-shot runs, completely eliminating edge peeling. |
| Elastic Soft Touch | Hardness 42 Shore A (10s) | Delivers an ultra-soft, warm, and highly tactile rubbery grip, ensuring patient comfort on medical device handles. |
| Medical Safety | USP Class VI & ISO 10993 Certified | Compliant with global biocompatibility regulations. Latex-free and phthalate-free, preventing extractable contamination. |
Structural Process & Bonding Configurations for Overmolding OM 1040X
With its highly shear-thinning melt viscosity and polar chemistry, Versaflex OM 1040X-1 bonds permanently:
| Molding Process Category | Process Compatibility & Operational Details |
|---|---|
| Biocompatible Medical Device Grips | Excellent. Runs inside our certified ISO Class 7/8 cleanrooms using high-purity translucent pellets to overmold medical syringe barrels, surgical tools, and dental instruments. |
| Low-Viscosity Gaskets & Seals | Excellent. With its low compression set (22% at 23°C), it is ideal for thin-walled diagnostic cartridge seals and medical ventilator gaskets. |
| Dynamic Electronics Overmolding | Good. Allows overmolding onto rigid PC or PC/ABS shells of handheld consumer electronics and medical displays, providing protective shock-absorbing bumpers. |
TPE-Avient GLS Versaflex OM 1040X Tooling & Peeling Prevention Guide
Molding an amorphous overmolding elastomer like Versaflex OM 1040X-1 requires strict thermal interface controls and precise parting line tolerances to prevent peeling:
Perfect Interfacial Adhesion (Eliminating Peeling)
Because OM 1040X-1 relies on chemical compatibility for thermal bonding, we avoid using PVC-based color carriers or dynamic mold release sprays on tool faces. Color concentrates must use EVA, PP, or LDPE carriers. Purging the barrel with low-flow PE or PP before runs is strictly required to protect adhesive purity.
Cold Mold Temperature Control
We maintain mold temperatures at 20°C–35°C (68°F to 95°F) using pressurized water chillers. Keeping tools cold is critical to freeze the soft elastomeric phase quickly, allowing for automatic, warp-free ejection. Melt temperatures are controlled at 190°C–210°C (374°F–410°F).
Micron-Level Flash Control (S136 Steel Cavities)
Due to the low viscosity of OM 1040X-1 under shear, the molten resin can flash easily. We construct cavities using premium S136 stainless steel hardened to 48–52 HRC and machined on our 5-axis CNCs. This ensures parting line clearances are kept strictly within 0.010mm to avoid flash.
High Isotropic Shrinkage Compensation
Versaflex OM 1040X-1 exhibits high shrinkage (typically 2.00% to 2.60%). Our tooling engineers conduct Moldflow analysis during DFM to balance gate designs, ensuring uniform material compaction to eliminate sink marks near thick-walled grips.
Key Application Fields for TPE-Avient GLS Versaflex OM 1040X
- Medical Device overmolded Consumables (ISO 13485): Biocompatible syringe plunger tips, soft-touch surgical instrument handles, diagnostic device housings, fluid-delivery manifold gaskets, and dental tool grips.
- Handheld Consumer Electronics: Impact-resistant smartphone bumper cases, smart-wearable straps, handheld terminal housings, power tool grips, and protective bezels.
- Industrial Dynamic Sealing: Low-pressure water gaskets, chemical-resistant soft washers, laboratory assay cartridge caps, and protective connector sleeves.
Properties
| Density | 0.918 - 0.920 g/cm³ |
| Melt Mass-Flow Rate (MFR) (190°C/2.16kg) | 9 g/10 min |
| Tensile Modulus (100% Strain) | 1.24 MPa |
| Tensile Modulus (300% Strain) | 2.08 MPa |
| Tensile Strength at Break | 3.47 MPa |
| Tensile Elongation at Break | 580 % |
| Tear Strength | 17.5 kN/m |
| Compression Set (23°C, 22h) | 22 % |
| Durometer Hardness (Shore A, 10s) | 42 - |
| Apparent Viscosity (200°C, 11200 s-1) | 11.7 Pa·s |
| Linear Mold Shrinkage (Flow Direction) | 2.00 - 2.60 % |
| Biocompatibility Compliance | USP Class VI / ISO 10993 - |
| Maximum Part Size (Cleanroom limit) | 600 x 400 mm |
| Minimum Part Size | 1 x 1 mm |