A Guide To Overmolding

helen84827
6 days ago
1 min read

In the fast-paced world of product development, overmolding has emerged as a game-changing technology for creating durable, functional, and aesthetically superior prototypes and short-run productions.

What is overmolding?

Overmolding is an advanced manufacturing process that combines two or more materials into a single, integrated component. It begins by molding a substrate (base layer) from rigid materials like plastic or metal, followed by injecting an overmold material—typically thermoplastic elastomer (TPE), silicone, or rubber—over the substrate.

Why does your project need overmolding?

Reduced costs by consolidating multi-part assemblies into one unit.

Faster time-to-market with integrated manufacturing workflows.

Real-world validation of material compatibility and ergonomics before mass production.

Material Selection Guide

Substrate Materials

Plastics: ABS (impact resistance), PC (transparency), PEEK (high-temperature stability)

Metals: Aluminum 6061 (lightweight), Stainless Steel (sterilizable), Brass (conductivity)

Overmold Materials

TPE/TPU: Soft-touch grips, shock absorption (e.g., tool handles, wearable devices)

Silicone: Biocompatible and heat-resistant (e.g., medical scalers, seals)

Custom Compounds: Colored, UV-stable, or flame-retardant formulations for specialized needs.

Industries Applications

Medical Devices

Ergonomic scalpel handles with non-slip silicone overmolds,

Sealed housings for diagnostic equipment.

Consumer Electronics

Drone controllers with shock-absorbing TPU edges,

Waterproof smartwatch casings combining PC + TPE.

Automotive & Industrial

Vibration-damped tool grips,

Multi-material gear shift knobs (metal base + textured TPE).

Ready to Elevate Your Product?

Whether you need a prototype for design validation or short-run production for market testing, our overmolding services deliver quality, speed, and innovation.