Advanced two-shot injection molding and multi-material solutions for enhanced functionality, durability, and aesthetics. From prototypes to high-volume production.
Overmolding is an advanced injection molding process that combines two or more different materials into a single, unified component. This technique involves molding one material (typically a soft elastomer like TPE) over a pre-existing rigid substrate, creating products with enhanced functionality, improved ergonomics, and superior aesthetics.
The process enables manufacturers to integrate multiple material properties into one part, eliminating assembly steps, reducing costs, and creating stronger, more durable products with better user experience.
We offer comprehensive overmolding solutions for various material combinations and applications
Combines rigid and flexible plastics for enhanced functionality and multi-color designs
Soft-touch elastomer over rigid substrate for superior grip and comfort
Protective plastic coating over metal components for corrosion resistance
Soft elastomer over metal for tool handles and grip applications
A systematic approach to multi-material manufacturing excellence
Create the core component using standard injection molding with rigid thermoplastic materials
Inspect substrate for dimensional accuracy, surface quality, and material integrity
Transfer substrate to overmolding station and position in secondary mold cavity
Inject second material (TPE/TPU) around or onto the substrate creating molecular bond
Allow proper cooling time for material bonding, then eject finished overmolded part
Comprehensive material selection for optimal performance and compatibility
| Overmold Material | ABS | PC | PA | PP | POM |
|---|---|---|---|---|---|
| TPE (Styrenic) | C | C | M | M | M |
| TPU | C | C | C | M | M |
| TPV | M | M | M | C | M |
Overmolding solutions across diverse industries and applications
Understanding the differences between manufacturing approaches
Essential considerations for successful overmolded parts
Comprehensive quality control throughout the overmolding process
Compatibility verification, thermal analysis, and mechanical properties testing
Adhesion testing, peel strength evaluation, and durability assessment
CMM measurement, tolerance verification, and geometric analysis
Surface quality assessment, color consistency, and cosmetic evaluation
Why choose overmolding for your next project
Improved impact resistance, wear protection, and extended product lifespan through multi-material construction
Soft-touch surfaces, non-slip grips, and enhanced comfort for better user experience and product usability
Reduced assembly operations, eliminated fasteners, and streamlined production for overall cost reduction
Multi-color designs, complex geometries, and creative material combinations for unique product differentiation
Excellent water resistance, chemical resistance, and environmental protection for demanding applications
Optimized material usage, hollow structures possible, and strategic material placement for weight savings
Real-world application of TPE overmolding technology
Development of an ergonomic toothbrush handle featuring PP substrate with TPE overmolding for enhanced grip and comfort during daily use.
Create a comfortable, non-slip grip while maintaining cost-effectiveness and aesthetic appeal
TPE overmolding on PP substrate with strategic grip zones and ergonomic finger contours
40% improved grip strength, enhanced user comfort, and 25% reduction in manufacturing costs
Common questions about overmolding services and processes
Overmolding involves molding one material (usually TPE) over a pre-molded plastic substrate to create a two-material part. Insert molding places pre-formed components (typically metal) into a mold before injecting plastic around them. Overmolding focuses on material bonding for enhanced functionality, while insert molding integrates disparate components.
Popular substrate materials include ABS, PC, PA (Nylon), and PP. Common overmold materials are TPE, TPU, TPV, and liquid silicone rubber (LSR). Material selection depends on required properties like flexibility, chemical resistance, temperature range, and bonding compatibility. We provide material compatibility testing to ensure optimal adhesion.
Lead times vary based on project complexity. Simple overmolding projects can be completed in 15-20 business days, while complex geometries or new material combinations may require 3-6 weeks. Prototype tooling reduces initial lead times, and we offer expedited services for urgent requirements.
We ensure strong bonding through material compatibility testing, proper surface preparation, mechanical interlocking features, and optimized processing parameters. Our design team incorporates undercuts, texturing, and geometric features that promote mechanical bonding, while chemical compatibility testing validates molecular adhesion.
Our quality control includes incoming material inspection, substrate dimensional verification, bond strength testing, visual inspection for defects, and final dimensional analysis. We maintain ISO 9001:2015 certification and provide detailed quality reports including material certificates, dimensional reports, and bond strength data.
Yes, overmolding is excellent for low-volume production due to lower tooling costs compared to two-shot molding. Our aluminum tooling solutions provide cost-effective production for quantities from 100 to 10,000+ parts. We also offer rapid prototyping services for design validation before committing to production tooling.
Absolutely. We offer medical-grade overmolding with ISO 13485 certification, biocompatible materials, and cleanroom manufacturing capabilities. Common medical applications include surgical instrument handles, drug delivery devices, diagnostic equipment, and patient interface components requiring soft-touch surfaces.
Professional CNC machining and custom parts manufacturing services, meeting your precision machining needs with rapid delivery of high-quality components.
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