Overmolding Process

The overmolding process adds an outer layer, usually a rubber material, to an existing component and creates one seamless assembled part. Consider a tool or other piece of hardware. In its original form, the product may look incomplete. Take a hammer as an example. Alone, the hammer would be functional, but it would lack any kind of protective grip which can help ergonomic use and reduce shock impact. With overmolding, the tool can have an extra coating added improving the product and making it ready for market


Overmolding Injection Moldings:

There are two typical ways to manufacture an overmold part. The first is adhesive bonding and the second is mechanical bonding. Plastimold uses the mechanical bonding method utilizing our plastic injection molding machines. In this process, the original product and the overmold are designed at the same time. The base (substrate) product has grooves, recessions or other physical properties that allow for the overmolded material such as rubber (TPU/TPE) to attach. Overmolding isn’t only for tools, it can also be used for cable ends, or to add a body or shell to consumer electronics.

  • Cable overmolding 
  • Plastic overmolding
  • Rubber overmolding
  • Low pressure overmolding 
  • Insert overmolding 
  • TPU and TPE overmolding

How your overmold design will save big money

One of the most significant benefits of plastic overmolding is a reduction in cost during manufacturing. Using the plastic injection molding process, you can create overmolded components in bulk that are ready for assembly. Injection molding creates little waste which can reduce total cost of manufacturing. Another benefit of minimal waste is the positive impact is has on our environment.

Versatility is another major benefit of choosing this process. Overmolding allows for limitless variations of shape and color design. Because plastics are color impregnated, there’s no need for painting or aesthetic finishing. Exactly what you design will mirror your end product, and consumers will enjoy a product that won’t fade or scuff, over time. The molding process also allows for design features like textured hand grips and ergonomic shapes. These features allow for easy and comfortable use of any product. Overmolding can also be used as an effective way to seal electronic products, tools, and other devices.

overmolding molding

Efficient Tooling Produces Quality Parts

The mold required to develop a single component only needs to be completed once, which reduces much of the cost in developing plastic components for your product. Not only does this make the process more efficient, but it also ensures consistency throughout the production run. Consistency is key to developing trust in your brand, and you can count on Plastimold to deliver consistent, quality results on any project.

Our engineers have the experience and knowledge necessary to produce efficient part designs ready for overmolding. We’ll work with you to turn your concept into reality.

Multi-axis machining