Versatile, precise, and cost-effective

Overmolding Services

High Quality Process for Pilot Runs, Low-Volume Production, and Bridge Tooling

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OUR EXPERTISE

Overmolding: Enhancing Product Performance And Aesthetics

Overmolding is a manufacturing process that involves molding two or more materials together to create a single component.
This process is used to improve the product’s functionality, aesthetics, and durability by incorporating different materials with varying properties into a single part. Overmolding can also be used to create a soft-touch grip or provide additional protection to electronic components.
The two-shot molding process is one particular type of overmolding. Nonetheless, at XTmade, we distinguish between these two. We usually 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 clients to select the most suitable materials and develop the optimal molding process for their project.

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Tolerances

Overmolding Services Provided

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

Why Is XTmade The Best Place For All Of Your OverMolding Needs?

We are the fastest prototyping, production, and molding company around. We can take your project from the prototyping phase to mass production in a matter of days.
We have the most comprehensive list of services in the industry. We are the only company that will stick with your project from the very beginning to the very end. We have all of the technology and experience necessary to be your one source for your project.
While we proudly take on large projects, we also welcome low volume production runs. If you have a small project that needs completed, we will gladly offer our comprehensive services.
We never close. We remain open every day of the year for twenty four hours a day. So, you can always come to us for a timely, high-quality, and efficient experience.

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Precision Injection Molding

XTmade Overmolding Solutions

XTmade takes on the challenging overmolding applications. From overmolded medical devices to industrial applications, plastic overmolded components provide superior performance. By overmolding plastic onto or into metal, or plastic onto plastic we are able to create a more-consistent and higher-quality product with superior performance. In addition, it can eliminate complicated assembly and post-molding processes.

With our expertise, we are able provide design feedback for your challenging overmold applications. Our engineers will work with your team to offer solutions that optimize your design concept.

Overmolded products provide:

Consistent and accurate alignment
Improved structural integrity
Reduced labor costs
Increased design flexibility
Higher quality and superior performance

Material Considerations

Of note, it is important to ensure that the plastic material for overmolding is chemically compatible with the substrate. When the overmold material does not chemically bond well with the substrate, the two materials can be mechanically bonded by incorporating holes or ribs on the surface of the substrate.

ABS
Acetal copolymer (POM)
Acrylic
HDPE
TPU

PBTR
PEEK
PEI
Polycarbonate
TPE

Overmolding Finishes

SPI Finishes
Range of finishes from Grade 3 diamond / high polish to 320 stone low polish. Finishes include: SPI A-1 SPI A-2 SPI A-3 SPI B-1 SPI B-2 SPI B-3 SPI C-1 SPI C-2 SPI C-3 SPI D-1 SPI D-2 SPI D-3

As Molded
No secondary polishing or grinding. Part will show tooling marks.

Other Mold Texturing
XTmade can match other mold textures upon request.

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. As everything happens in a single operation, the need for assembly is eliminated. Although, this process may sound similar to two-shot molding, its single step process sets the two appart.
Common applications include creating two-tone aesthetics, gaskets and seals, and adding grips and buttons or hardware components to plastic parts.

Overmolding Design Tips

Wall thicknesses between 0.060″ to 0.120″ (1.5 mm-3 mm) generally provide the best bonding.
Keeping radii between 0.020″ or 0.5mm minimum in corners reduces localized stresses.
If the part requires the use of thick TPE sections, they should be cored out to minimize shrinkage problems, reduce the part weight and lower cycle time.
Avoid deep or un-ventable blind pockets or ribs in your design.
Use gradual transitions between wall thickness to reduce or avoid problems with flow (back fills, gas traps, etc.)
The TPE/TPV should be less thick than the substrate to prevent warpage, especially if the part is flat, long, or both.
Overmolding needs mechanical or chemical bonding to the substrate, so your overmold material choices should enable this.

Our Overmolding Service for Various Industries

XTmade works with leading manufacturers from different industries to support growing demands and streamline their supply chain. The digitalization of our custom injection molding services helps more and more manufacturers bring their idea to products.