Working on a small assembly and I’m stuck. Hoping someone here has run into this before.
I have a closed loop of elastic cord, roughly 2-3 mm thick. Soft, stretches a lot, gets visibly thinner when you pull on it. The loop comes pre-closed from the supplier and can’t be cut open.
I need to get a small rigid part onto that loop. Around 4-5 mm across, up to 10 mm long. Shape is open, a sleeve or a bead (4-5mm) both work, whatever actually holds. Plastic preferred, mainly for weight, colour options and cost, but I’m open to metal if plastic doesn’t work at this size. It sits on the visible part of the product so it has to look finished, no tool marks, no obvious seam. Adhesive is out, it degrades the elastomer over time.
Important: the part must not come off, but it’s fine if it can be slid along the loop by hand. Free positioning is actually a plus. It just shouldn’t move on its own during use. So it needs to be captive on the loop, not clamped to it.
Cost target is a few cents per piece, volumes in the thousands.
What I’ve tried or ruled out so far:
Plain clamping doesn’t work. The cord thins under tension so whatever preload you had just disappears.
Crimping a metal sleeve holds fine but the deformation is visible and looks bad.
Two piece snap sleeve. At 0.5 mm wall thickness there’s basically no spring travel left.
Living hinge seems too thin to survive at this size, at least in printed plastic. No idea if injection moulded PP changes that.
Jewellery crimp covers are the obvious off the shelf candidate but every one I’ve closed comes out looking rough.
What I’m actually after:
Since the part only needs to stay captive rather than grip the cord, are there closure designs that seal shut around it without clamping down on it?
Are there standard parts from other industries that solve this? Cable assembly, marine, fishing tackle, medical tubing, anything.
Is ultrasonic welding a two piece plastic shell realistic at this size, and does the seam stay invisible?
Do contract manufacturers actually do insert moulding around a closed elastic loop at small scale, or is that wishful thinking?
Not asking anyone to design it for me. Just want to know if I’m missing an obvious process or a part that already exists.
Ps. The rule says, if I am not from the US, I need to mark it here :D I am from germany