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What is Overmolding?
Overmolding Process
Plastic over Plastic
Crucial for mass production, involves machining, and assembling durable molds from steel or aluminum to ensure precise and repeatable part geometries.
- Aluminum and steel injection mold.
- Achieves detailed geometries.
- Ideal for mass production.
Rubber Over Plastic
Overmolding improves product functionality and aesthetics by fusing different materials into one part, adding features like soft grips and multi-color designs for enhanced usability
- Improves strength and lifespan.
- Combines different materials seamlessly.
- Offers color and texture options.
Plastic Over Metal
Insert molding integrates metal or other materials into plastic parts during molding, enhancing strength and reducing assembly time for components with embedded features.
- Reduces assembly steps.
- Enhances component durability.
- Lowers production expenses.
Rubber Over Metal
Insert molding integrates metal or other materials into plastic parts during molding, enhancing strength and reducing assembly time for components with embedded features.
- Reduces assembly steps.
- Enhances component durability.
- Lowers production expenses.
Overmolding
Tooling Solutions
Rapid Tooling
Get easy design feedback and validation through superior quality prototype tooling. Create small batches of plastic molded parts with excellent injection molding prototypes. We excel at manufacturing prototype molds within days to ensure you perform functional tests and validate market interest.
Our molds with steel cavities and cores typically have a shot life of 1,000 to 5,000 shots and can be manufactured within two weeks.
Production Tooling
We create high-quality production molds for high-volume plastic parts production. With high-strength, durable tool steel material, our production tooling is suitable for producing hundreds of thousands of parts. We can vary materials and construction methods according to your unique requirements.
Our high performance steel tool is capable of enduring up to 10,000 shots, and generally parts can be produced within 3 weeks.
RapidDirect's Overmolding Finishes
Overmolding
Capabilities
RapidDirect’s custom overmolding services ensure the creation of plastic parts that look and perform better. Our production line consists of an overmolding injection molding process that allows us to combine several different materials into one, ensuring you get superior-quality products.
| Standards | Description |
|---|---|
| Maximum Part Size | 200×400×100mm 7.87×15.75×3.94 in. |
| Manimum Part Size | 2×2×2mm 0.08×0.08×0.08in |
| Substrate Wall Thickness | From 0.5 to 3mm From 0.20 to 0.12 in. |
| Tolerance | +/- 0.025 mm +/- 0.00098 in. |
| Radii | 0.1mm 0.0039in. |
| Depth | 100mm from the parting line 3.94 in. from the parting line |
| Mold Validation | Provide T0, T1, T2 samples before mass production |
| Inspection and Certification Options | First Article Inspection, ISO 9001, ISO 13485 |
| Lead Time | From mold making to sample delivery: 15-45 business days |
Advantages of Overmolding
Overmolding enhances product durability and functionality by integrating different materials, offering improved grip, aesthetics, and cost-effective assembly.
- Improved Design and Creation of Custom Plastic Parts: Overmolding capabilities ensure the creation of custom plastic-plastic or metal-plastic product combinations with a high dimensional quality.
- Better Product Performance: Overmolded parts are of excellent quality because of their two-material advantage for various applications.
- Increased Shelf and Aesthetic Appeal: The overmolding process can be optimized with many materials and surface treatment processes to improve the aesthetic quality of the product.
- Better Shock Absorption and Overall Durability: Overmolding also offers improved shock absorption due to the plastic resin addition, ensuring longer shelf life and excellent resistance against impacts.
- Lower Production Costs: Since overmolding eliminates post-assembly phase of production, it speeds up the production process and reduces overall manufacturing cost.
Applications of Overmolding
The injection overmolding process is compatible with a wide variety of materials, ranging from plastics to metals. This process helps produce custom prototypes and production parts for various applications depending on your requirements. Several industries find valuable uses for overmolding services.
- Surgical Instruments: Overmolding meets the precision and safety requirements of the medical industry. The ability to combine plastics and metal materials ensures the efficient creation of surgical devices, equipment housing, catheters, syringes, and more.
- Electrical Applications: Using thermoplastic elastomer as an overmold material makes the process useful for electrical components. Custom-made overmolded parts, like electrical outlet covers, gaskets, etc., are made to withstand harsh conditions, making them last longer.
- Hardware Tools: The functional advantages of overmolding make it an outstanding process for making pliers, screwdrivers, hammers, wrenches, pocket knives, and more. The process improves the grip of these tools, making their application more efficient.
- Household Items: The overmolding technique generally improves functional performance like grip, cleanliness, and ease of use. It also enhances vibration dampening, chemical resistance, and more. This makes them useful for household items like kitchen utensils, toothbrushes, pens, shampoo bottles, etc.
Overmolding
vs Insert Molding
While there are various similarities between overmolding and insert molding, there are also certain differences you must note. Here’s a video to explain the vital differences between these valuable processes.
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