Overmolding Injection Molding Service
What is Overmolding
Overmolding is a process of taking a substrate part and then using injection molding to add additional layers over it, like thermoplastic or silicone rubber material. Traditionally, the substrate parts are plastic or metal with a higher melting point, once that part is cooled, the layer is injection molded over it. So the cycle time is a bit longer. Usually overmolding is used to create a grip or roller.
Overmolding Process
Overmolding is a multi-step manufacturing technique used to create complex, multi-material components.
- Initial Substrate Molding: The base or substrate part is first created using standard injection molding techniques.
- Substrate Preparation: The molded substrate is prepared, which may include cleaning and conditioning, to ensure proper adhesion for the overmolding process.
- Overmolding: The substrate is placed into a second mold where the overmold material is injected over or around it, forming a bond with the substrate.
- Cooling and Ejection: The assembled part is allowed to cool and solidify before being ejected from the mold, completing the overmolding process.
Overmolding Material
Substrate material for overmolding
Overmolding is commonly used to encapsulate one material (usually a softer or elastomeric material) over another rigid substrate. The most common substrate material for overmolding is thermoplastic, these material provides a stable base of overmolded components, the most common substrate material include:
- ABS
- PC
- Nylon
- PP
- ABS/PC
Bonding material for overmolding
The most common overmolded material is thermoplastic elastomer, known for its flexibility, resilience, and compatibility with various substrates. Some other common bonding materials include:
- TPE
- TPU
- TPV
- Silicone
Advantages of Overmolding
- Overmolding provides a protective layer, improving the overall durability and lisfespan of the product.
- Enables the incorporation of multiple materials with varying properties, enhanding design possibilities.
- Allows for the creation of ergonomic and comfortable surface for products like grips and handle.
- Eliminate the need for additional assembly steps, steamlining the manfuacturing process.
Application of Overmolding
Overmolding is widely used across various industries due to its ability to enhance product functionality and aesthetics by combining multiple materials. Common applications include:
- Cable connectors
- Soft-touch grips on devices
- Buttons
- Handles
- Protective housing
- Toothbrushes
Why Choose Us
Contract Manufacturing Solution
Mold & Tooling Service
Design for Manufacturability
Surface Finishing
Assembly Manufacturing
FAQs of Overmolding
What is the difference between overmolding and insert molding?
What is the difference between two-shot molding and overmolding?
Two-shot molding usually only makes sense for larger production runs, whereas overmolding is better for low volume production runs.
Is overmolding expensive?
Overmolded parts are made in two-step process. This increases part cycle time and is thus more expensive than molding a single part with no overmolding.
