Sensor housings
Soft backs that hold a sensor against skin comfortably.
Overmoulding · Wearable overmould
Wearable overmoulding.
Wearables have to be tough, sealed and comfortable against skin all day. Overmoulding silicone onto a rigid frame gives you all three in one part.
The detail
Comfort, sealing and strength together
A wearable part often needs a rigid core for structure — a clasp, a sensor carrier, a button backing — with soft silicone where it touches skin and where water must be kept out.
We use skin-contact silicone grades, finish the tool surface to the feel you want, and design the bond so it survives sweat, drops and years of flexing. See our wearable and consumer page for the wider picture.
Where it fits
Where it's used
Buttons and controls
Sealed buttons moulded onto a rigid backing.
Straps with rigid parts
Buckles and lugs moulded into silicone bands.
How we run it
How we run it
Feel samples
Surface finish and hardness samples so you can choose the feel.
Grade selection
Skin-contact grades with documentation.
Overmould with interlocks
Mechanical locks plus a chemical bond where possible.
Durability checks
Bond and flex testing, with sweat or cleaning agents if relevant.
To quote it
To quote it
The rigid part
Drawing and material.
How it's worn
Wrist, ear, chest, skin contact duration.
Finish and colour
Matte, silky, gloss; colour references.
Launch plan
Pilot quantities and expected ramp.
At a glance
The idea in a picture.
How overmoulding works
Swipe to see the whole diagram
Questions
What people usually ask.
Will skin-contact silicone cause reactions?
Skin-contact grades are chosen for low irritation. We'll share the supplier's documentation, and you'll assess suitability for your product.
Can you add a logo into the silicone?
Yes, moulded-in, debossed or printed. See printing and marking.
Keep exploring
More from overmoulding.
Substrate overmould
Your rigid part arrives, goes into our tool, and leaves with silicone permanently attached. No glue line, no assembly step, no seal to fall…
Open this variantCable and connector overmould
The point where a cable enters a connector or device is where most cables fail. An overmoulded silicone body seals that point, spreads the…
Open this variantOvermoulding overview
Silicone or rubber moulded directly onto a pre-made substrate — a plastic housing, a metal insert, a printed circuit assembly — so the…
Back to the overviewDesigned and developed in the UK. UK moulding capability, with some higher-volume production placed with trusted partners where that's the right commercial answer.
Get in touch
Tell us the part, the volume, and the timeline.
Rough annual volume, target unit price, and any deadlines. That's enough to work out whether compression, LSR injection or something else is the right tool.
Real people, a real workshop
You deal with the people who make it.
No call centre and no middlemen. When you contact TCI Products, you speak to the team who design, build and check your mould.
- A real Warwickshire workshopUnit 15, Waterloo Park, Bidford-on-Avon, Alcester B50 4JG.
- Real people on the phoneCall the team on 01789 224228, Monday to Friday.
- The same team on every jobDesign, production and aftercare come from the people you see here.
- Part of TCI GroupFive specialist brands, one engineering team. Visit TCI Group.
Thomas LaneManaging Director
George PrestonDesign & Project Manager
Kelly BallingerHead of Partnerships
Jim AndertonProduction Manager
TheodoreEmployee Welfare