Military & Security Product Prototype – CNC Aluminum Alloy + Soft Glue Overmolding | YYI Tech

Product Overview:

YYI Tech specializes in CNC machining and hybrid-material prototyping for the military and security industries. Our Aluminum Alloy + Soft Glue prototype processing service is tailored for developing rugged, ergonomic, and durable components used in field equipment, control housings, communication gear, and more. We combine high-strength aluminum cores with soft-touch or shock-absorbing rubber-like materials (TPU, silicone, or TPE), providing enhanced protection and user comfort in mission-critical environments.

Materials & Technology:

• Hard Material (Core): Aerospace-grade Aluminum Alloys (6061, 7075, etc.)

• Soft Material (Overmold/Insert):

  • TPU (Thermoplastic Polyurethane): Flexible and abrasion-resistant

  • Silicone: High-temperature, non-slip, and chemical-resistant

  • TPE (Thermoplastic Elastomer): Excellent tactile and sealing properties

• Integration Methods:

  • CNC + Manual Insert Molding

  • CNC + Overmolding via compression or injection

  • Bonded dual-material assembly for prototypes

Manufacturing Capabilities:

• Machining: 3/4/5-axis CNC for metal cores

• Soft Material Process: Manual casting, vacuum forming, or low-pressure injection (depending on part size)

• Tolerances: ±0.01 mm for metal, ±0.1 mm for soft material (depending on geometry)

• Rapid Prototyping: From 1 to 100+ units

• Design Support: DFM feedback for moldability and dual-material compatibility

Applications in Military & Security:

• Rugged handheld device housings

• Protective grips for firearms, drones, or surveillance tools

• Shock-absorbing mounts or brackets

• Sealed control enclosures or sensor covers

• Wearable tactical components (soft-touch + armored)

Selling Points & Advantages:

• Dual-Material Expertise: Metal strength + soft material comfort/shock resistance

• Custom Ergonomics: Optimized for grip, sealing, and protection in field conditions

• Precision Fit: CNC accuracy ensures seamless integration of soft and hard components

• Ruggedization for Harsh Environments: Resistance to vibration, water, dust, and impact

• Prototyping to Pilot Production: Small runs for testing or low-volume end-use

FAQs:

Q1: What’s the benefit of combining aluminum with soft glue materials?
A: The aluminum provides structural integrity, while the soft glue (like TPU or silicone) offers grip, shock absorption, or environmental sealing—ideal for military-grade equipment.

Q2: Can YYI Tech help with insert-molding design review?
A: Yes. We offer DFM (design for manufacturability) consultation to ensure optimal bonding and part function.

Q3: How durable are the bonded materials in prototype form?
A: With proper prep and bonding techniques, our aluminum + soft glue prototypes can withstand rough handling and environmental exposure suitable for field tests.

Q4: What surface treatments are available for the aluminum parts?
A: We offer anodizing, sandblasting, painting, or powder coating for added corrosion resistance and aesthetics.

Q5: What’s the lead time for dual-material prototypes?
A: Typically 7–14 days depending on complexity, volume, and the bonding method chosen.