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Prototype overmolding is a unique plastic injection molding technology, which allows various materials to be seamlessly molded into a single part or product. China overmolding is usually composed of hard plastic base components, coated with rubber-like thermoplastic elastomer (TPE) external layer or other materials. The prototype overmolding process is slightly different from insert molding in that it uses a combination of two or more plastic or elastomeric materials to produce a single part. Plastic overmolding helps reduce manufacturing time by molding a second part directly onto the original part, instead of having to manufacture both parts entirely separately and then assemble them.

Our Injection Molding Services - Quality Overmolded Plastic Parts Manufacturing 

As one of the leading rapid injection molding manufacturers in China, we provide end-to-end plastic injection overmolding services to ensure the success of your project. From part feasibility to mold design to final manufacturing, our project manager will work with you to give the perfect solution for your specific requirement. With a wide range of materials at our disposal and advanced equipment, YS offers highly customized plastic injection overmolding services to meet all your project needs.

How Does Injection Overmolding Work? 

Rapid overmolding is the technology of layering materials on a part to provide strength, longevity, or aesthetic benefit. Like complex plastic injection molding, injection overmolding is completely according to customer’s needs, as customized products are easy to manufacture and design at the mould tool design stage. It is very popular China precision machining technique because it is fast and cheap to mass produce the parts with high quality.

This injection mould tool leaves room to inject the second material. When the second material is injected into the mold, the two components are cured to create the final overmolded product. However, if an error occurs at any stage, the entire process has to be redone.

Injection overmolding is the technology of layering materials on a part to provide strength, longevity, or aesthetic benefit. Like plastic injection molding, injection overmolding is completely according to customer’s needs, as customized products are easy to manufacture and design at the mould tool design stage. It is very popular technique because it is fast and cheap to mass produce the parts with high quality.

What Are Benefits of Injection Overmoling Services?

Plastic injection overmolding helps reduce manufacturing time by molding its second part directly onto the original part, instead of having to manufacture two parts completely separately and then assemble them together. Other benefits of plastic injection overmolding are as following:

Improved grip and ergonomics

provides electrical insulation

Forms a waterproof seal

Sound absorptionibration suppression

Overmolding Design Guidelines

Our basic guidelines to overmolding includes key design considerations that help improve part manufacturability, improve appearance, and reduce overall production time.

Max. SIZE480mm x 751.8mm x 203.2mm
Max. VOLUME966837 cu. mm
DEPTH101mm from parting line
Up to 203.2mm if the parting line can pass through the middle of the part
PROJECTED MOLD AREA112903 sq. mm (plastic)
30968 sq. mm (silicone rubber)

Overmolding Materials
Most Common Materials for Overmolding:

ABS-Acrylonitrile Butadiene Styrene

PE-Polyethylene

PP-Polypropylene

PC-Polycarbonate

Other Common Supported Materials:

Nylon (PA 6, PA66, PA 12)

"Polycarbonate/Acrylonitrile Butadiene Styrene(PC/ABS)"

Polyurethane (PU)

Polymethyl Methacrylate (PMMA/Acrylic)

High Density Polyethylene (HDPE)

Low Density Polyethylene (LDPE)

Polystyrene (PS)

POM (Acetal/Delrin)

Polyetherimide (PEI)

Polysulfone (PSU)

Thermoplastic Elastomer (TPE)

Using silicone as an overmolding material can limit the height, confining deeper areas to smaller profiles. Minimum part volume is 40.98 cubic mm. A machining tolerance of ±0.08 mm can be maintained by using a substrate mold. This includes a resin tolerance of 0.002mm. For thermoplastic overmolding, the tolerance is the same as for the base mold, but if the overmolding is LSR, the tolerance is 0.025mm.

Injection Overmolding Material Compatibility And Mechanical Bonding
Chemical bonding between overmolded materials is possible, but material compatibility must be considered to achieve the required bond strength. If adhesion is important to your application, incorporating a suitable mechanical bond is highly recommended. Undercuts are a good example of mechanical bonds.
Substrate Material
Overmold MaterialABS LustranABS/PC CYCOLOY C2950-111PC Lexan940-701PBT Valox357-1001PP Profax6323
TUP-Texin
983-000000Chemical bondChemical bondChemical bondChemical bondMechemical bond
101-87Mechemical bondMechemical bondMechemical bondMechemical bondChemical bond
TPE-Santoprene101-64Mechemical bondMechemical bondMechemical bondMechemical bondChemical bond
LAR-Elastosil3003/30A/BMechemicalbondMechemical bond
TPC-Hytrel3078Chemical bondChemical bondChemical bondChemical bondMechemical bond
TPE-VersaflexOM10601Chemical bondChemical bondChemical bondMechemical bondMechemical bond
TPE-VersaflexOM6240-1Mechemical bondMechemical bondMechemical bondMechemical bondMechemical bond
TPE-VersaflexOM6258-1Mechemical bondMechemical bondMechemical bondMechemical bondMechemical bond
TPE-VersaflexOM1040X-1Chemical bondChemical bondChemical bondMechemical bondMechemical bond

If you are looking for a reliable precision machining factory, don't hesitate to contact us!