Versatile, precise, and cost-effective
Overmolding Services
Providing high quality custom overmolding services for prototypes and on-demand production parts. We also offer rapid tooling services. Send us your design and get a free quote.
OUR EXPERTISE
Overmolding: Improving product performance and aesthetics
Overmolding is a manufacturing process that involves molding two or more materials together to create a single component. The process is used to improve the functionality, aesthetics, and durability of a product by combining different materials with different properties into a single part. Overmolding can also be used to create soft-touch grips or provide additional protection for electronic components. The two-shot molding process is a special type of overmolding. Nonetheless, at Xtmade, we distinguish between the two. We generally refer to the overmolding process as an injection molding process that requires two injection cycles to complete. Our team of experienced engineers and technicians work closely with our customers to select the most appropriate materials and develop the best molding process for their projects.
Our Capabilities
- Plastic over Plastic Substrate
- Rubber over Hard Substrate Overmolding
- Plastic over Metal
- Multi-Color
- Plastic Over Custom Inserts of any Material
- Chemical Bond Overmolding
- Plastic over Threaded Inserts
- Mechanical Bond Overmolding
- Medical instrument Overmolding
- Electronic Overmolding
- Wire Overmolding
Xtmade Overmolding Solutions
Xtmade can take on challenging overmolding applications. From overmolded medical devices to industrial applications, plastic overmolded parts deliver superior performance. By overmolding plastic onto or into metal, or overmolding plastic onto plastic, we are able to create more consistent, higher quality products with superior performance. Additionally, it eliminates complex assembly and post-molding processes. With our expertise, we are able to provide you with design feedback on your overmolding applications. Our engineers will work with your team to provide solutions that optimize your design ideas.
Overmolded products provide:
1. Consistent and accurate alignment
2. Improved structural integrity
3. Reduced labor costs
4. Increased design flexibility
5. Higher quality and superior performance
Ready to get started? Let us quote your next project.
We’ll make your next overmolding project less of a hassle, as these projects can be very complex. Send us your drawings today for a quote and DFM analysis.
What is Plastic Overmolding?
Overmolding involves molding plastic on plastic or plastic on metal to create a high-strength bond between the injection molded part and the overmolded part. Since everything is done in one operation, no assembly is required. While the process may sound similar to two-color molding, its single-step process makes the two distinct. Common applications include creating two-color aesthetics, gaskets and seals, and adding handles and buttons or hardware components to plastic parts.
Why Xtmade is your choice for all your overmolding needs?
We are the fastest prototyping, production and molding company. We can advance your project from the prototyping stage to the mass production stage in a few days. We are a one-stop company that can complete your project. We also have all the technology and experience you need for your project.
While we proudly undertake large projects, we also welcome small batch projects. If you have a small project that needs to be completed, we will be happy to provide comprehensive services. We are open at all times. You can always enjoy a timely, high-quality and efficient experience.
Overmolding Design Tips
- Wall thicknesses between 0.060 in. and 0.120 in. (1.5 mm to 3 mm) generally provide suitable bonding.
- Keeping the radius at corners between 0.020 in. or at least 0.5 mm reduces local stresses.
- If a part requires a thick TPE section, it should be hollowed out to minimize shrinkage issues, reduce part weight, and reduce cycle time.
- Avoid deep or unvented blind pockets or ribs in your design.
- Use gradual transitions between wall thicknesses to reduce or avoid flow issues (backfill, air traps, etc.)
- The thickness of the TPE/TPV should be less than the substrate to prevent warping, especially if the part is flat, long, or both.
- Overmolding requires mechanical or chemical bonding to the substrate, so your overmolding material selection should be able to achieve this.
Industries We Serve
Xtmade works with leading manufacturers in different industries to support growing demand and streamline their supply chain. Our custom injection molding services help more and more manufacturers turn their ideas into products.
Automotive
Medical
Aerospace
Consumer products
New Energy
Industrial machinery
Want to Start overmolding Project Today?
We provide high standard overmolding services, supporting small batch manufacturing, fast delivery and quick response within 24 hours.
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