Coated driver and method of forming

A combination of a socket and a driver for engaging the socket, the socket including a cavity defined by a coupling surface, the driver comprising:

• a core including a plurality of exterior core surfaces;
• the core made of a metal-based material;
• a casing encasing the plurality of exterior casing surfaces;
• the casing made of a polymer material;
• wherein the driver is configured to engage the socket via the casing in contact with the coupling surface;
• wherein:
• the plurality of exterior core surfaces includes a plurality of faces and a plurality of corner chamfers;
• each corner chamfer is intermediate one of the faces and another of the faces;
• the casing is adhered to the plurality of faces and the plurality of corner chamfers and is defined by a convex contoured surface relative to the plurality of faces.

A method for engaging a driver in combination with a socket, the socket including a cavity defined by a coupling surface, the method comprising:

• providing a driver, wherein the driver includes:
• a core including a plurality of exterior surfaces;
• the core made of a metal-based material;
• a casing encasing the plurality of exterior surfaces;
• the casing made of a polymer material;
• inserting the driver into the cavity such that the casing is in contact with the coupling surface;
• wherein:
• the plurality of exterior core surfaces includes a plurality of corner chamfers;
• the casing includes a plurality of corner portions, each corner portion encasing a respective corner chamfer;
• wherein the corner portion of the casing is characterized by:
• a rounded contour in a first plane normal to the corner chamfer;
• and
• a convex contour in a second plane normal to the corner chamfer;
• wherein the second plane is normal to the first plane.

A method for engaging a driver in combination with a socket, the socket including a cavity defined by a coupling surface, the method comprising:

• providing a driver, wherein the driver includes:
• a core including a plurality of exterior surfaces;
• the core made of a metal-based material;
• a casing encasing the plurality of exterior surfaces;
• the casing made of a polymer material;
• inserting the driver into the cavity such that the casing is in contact with the coupling surface;
• the plurality of exterior core surfaces includes a plurality of faces and a plurality of corner chamfers;
• each corner chamfer is intermediate one of the faces and another of the faces;
• the casing is adhered to the plurality of faces and the plurality of corner chamfers and is defined by a convex contoured surface relative to the plurality of faces.