Advanced Overmolding Services
Overmolding is essential for tooling, electronics, and healthcare industries combining materials. Common products:
- Soft-grip tool handles
- Sealed electronic connectors
- Medical device grips
- Dual-material automotive buttons
- Wear-resistant gear covers
- Consumer product ergonomic interfaces
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Service
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Insert OvermoldingPrecisely encapsulates metal/plastic inserts via secondary injection (±0.2mm tolerance). Essential for automotive bushings and waterproof connectors. -
Double Shot MoldingCombines two materials in one cycle (e.g., ABS+TPE) with <0.05mm layer precision. Standard for ergonomic tool handles and electronics. -
Co-InjectionSimultaneously molds core/skin layers (e.g., recycled PP core + virgin ABS skin), reducing weight by 15-30%. Critical for food packaging and automotive parts. -
Sequential MoldingMulti-stage process for complex geometries (e.g., rigid-to-flexible transitions). Cycle times increase 20-40% versus standard methods.
Our Advanced Overmolding Parts
Combining TPE/TPU with rigid substrates through multi-shot molding, we create ergonomic grips, seals, and vibration-damping components. Our robotic cells maintain 0.05mm bonding accuracy for medical devices and industrial controls.
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10+ Years of Overmolding ServicesTolerances as tight as ±0.0004 in.（0.01mm）MOQ as low as only 1 pc.Lead time:T1 samples as fast as 2 weeks -
210+ Years of Overmolding ServicesTolerances as tight as ±0.0004 in.（0.01mm）MOQ as low as only 1 pc.Lead time:T1 samples as fast as 2 weeks -
310+ Years of Overmolding ServicesTolerances as tight as ±0.0004 in.（0.01mm）MOQ as low as only 1 pc.Lead time:T1 samples as fast as 2 weeks
Overmolding Materials
Bonding TPE/TPU (Shore 30A-90A) to PC/ABS substrates with chemical/mechanical adhesion solutions. Medical-grade silicone overmolding available for soft-touch surfaces compliant with FDA 21 CFR and ISO 13485 standards.
Metals
Lightweight, high thermal conductivity, Excellent Machinability, Superior Dimensional Stability, Tight-Tolerance Capable, Perfect for Complex CNC Milling and Turning.
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Tolerances: ±0.005″ (±0.125mm)
Max part size: 200 cm x 80 cm x 100 cm
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Tolerances: ±0.005″ (±0.125mm)
Max part size: 200 cm x 80 cm x 100 cm
Golden aesthetic, good machinability, moderate corrosion resistance, often used for decorative hardware.
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Superior wear resistance, seawater corrosion resistance, classic metallic luster, commonly cast.
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High thermal/electrical conductivity, antimicrobial surface, develops natural patina over time.
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High strength-to-weight ratio, magnetic properties, requires coating for rust prevention.
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Chromium-enhanced corrosion resistance, heat-resistant, maintains strength in extreme conditions.
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Extremely lightweight (67% aluminum density), good vibration damping, requires surface treatment.
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Aerospace-grade strength, biocompatible, seawater corrosion resistance, difficult to machine.
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Plastics
Fast-flowing melt, low shrinkage (0.4-0.7%), requires pre-drying (80°C/4h), ideal for automotive dashboards and consumer electronics housings.
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High melt viscosity (300-350°C processing), moisture-sensitive (0.02% max), optical-grade clarity for LED lenses and medical device components.
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High mold temperature (60-80°C) reduces internal stress, low warpage, replaces glass in automotive taillights and cosmetic packaging.
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Crystallization-sensitive cooling (80-120°C mold), high dimensional stability, precision gears and fuel system valves.
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Moisture absorption (2.5-3.5%) requires post-molding annealing, self-lubricating bushings and automotive cable ties.
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Low melt strength (LDPE: 160-240°C), high flow rate for thin-wall containers and chemical-resistant pipeline fittings.
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Extreme processing temps (380-400°C), low shrinkage (0.1-0.3%), aerospace bushings and surgical sterilization trays.
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Fast crystallization (mold temp 60-80°C), glass-fiber reinforced connectors in automotive ECU housings.
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Low density (0.9g/cm³), living hinge capability, disposable syringes and automotive HVAC ducts.
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Non-melt flow (sintering required), ultra-low friction coatings for semiconductor seals and non-stick cookware linings.
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Overmolding Services Tolerances and Standards
With professional project managers and engineers in overmolding, we help to make your project come true from design to production. Worldsoaring’s overmolding service is dedicated to ensuring your product’s better performance.
Overmolding Surface Finishes
Looking for the right finish? Choose from 20+ options to meet both your functional and aesthetic needs.
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As MachinedDescription: Standard finish with surface roughness of 3.2 μm (126 μin), removes sharp edges and deburrs parts cleanly. Key Use: Functional parts requiring no post-processing (e.g., brackets, gears). Process Tolerance: Dimensional ±0.1 mm, Ra 3.2±0.5 μm Process Specifications: ISO 2768-m standard, burr height ≤0.05 mm
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AnodizingDescription: Electrochemical oxide layer for corrosion resistance and aesthetics. Process Compatibility: Post-machining surface treatment Key Use: Aerospace components, consumer electronics (e.g., phone frames). Process Tolerance: Coating thickness 10-25 μm±2 μm, color consistency ΔE≤1.5 Process Specifications: MIL-A-8625 or ISO 7599, sealing pH 5.5-6.5
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AlodineDescription: Chemical film for corrosion protection and paint adhesion. Process Compatibility: Post-cleaning chemical immersion Key Use: Aviation and automotive electrical housings. Process Tolerance: Film thickness 0.5-3 μm, visual uniformity Process Specifications: Immersion time 3-10 min, bath temp. 20-30℃
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Black OxideDescription: Thin magnetite layer for corrosion resistance and reduced glare. Process Compatibility: Post-machining chemical treatment Key Use: Tools, firearms, automotive fasteners. Process Tolerance: Coating thickness 0.5-1.5 μm, salt spray ≥24 hrs Process Specifications: Alkaline bath pH 13-14, process time 5-30 min
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BrushingDescription: Linear abrasive finish for decorative texture. Process Compatibility: Manual/CNC abrasive belts Key Use: Appliance panels, architectural trims. Process Tolerance: Texture depth 0.05-0.2 mm, angle deviation ≤5° Process Specifications: Abrasive belt grit 80-240, feed speed 10-30 m/min
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EtchingDescription: Chemical/mechanical removal for micro-texturing or marking. Process Compatibility: Laser/chemical masking Key Use: Circuit boards, decorative logos. Process Tolerance: Etch depth 0.01-0.5 mm±5%, alignment ±0.1 mm Process Specifications: Etchant concentration 10-30%, laser power 20-100 W
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Electroless PlatingDescription: Uniform metal coating (e.g., nickel) without electricity. Process Compatibility: Chemical bath deposition Key Use: Wear-resistant industrial valves, connectors. Process Tolerance: Coating thickness 5-50 μm±5%, porosity ≤5/cm² Process Specifications: Bath temp. 85-95℃, pH 4.5-5.5
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ElectroplatingDescription: Electrochemical metal coating (e.g., chrome, zinc) for durability. Process Compatibility: Post-machining electrodeposition Key Use: Automotive trim, jewelry. Process Tolerance: Coating thickness 5-25 μm±2 μm, adhesion ≥4B (ASTM B571) Process Specifications: Current density 1-10 A/dm², bath temp. 40-60℃
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ElectrophoreticDescription: Polymer coating via electric field for corrosion resistance. Process Compatibility: Post-cleaning immersion Key Use: Automotive frames, HVAC components. Process Tolerance: Coating thickness 15-30 μm±3 μm, edge coverage ≥80% Process Specifications: Voltage 50-300 V, cure 160-200℃×20 min
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GrindingDescription: Precision abrasive finish for tight tolerances. Process Compatibility: Surface/cylindrical grinding Key Use: Bearing races, hydraulic shafts. Process Tolerance: Dimensional ±0.005 mm, Ra 0.4-0.8 μm Process Specifications: Wheel grit 60-120, coolant flow 5-20 L/min
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Heat TreatmentDescription: Thermal process to alter material hardness/toughness. Process Compatibility: Post-machining quenching/tempering Key Use: Gears, cutting tools. Process Tolerance: Hardness HRC 45-60±2, distortion ≤0.1% Process Specifications: Quench temp. 800-1000℃, temper time 1-4 hrs
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KnurlingDescription: Diamond or linear pattern for improved grip. Process Compatibility: CNC lathe rolling Key Use: Handles, adjustment knobs. Process Tolerance: Pattern depth 0.2-0.5 mm, pitch ±0.05 mm Process Specifications: Roller pressure 200-500 N, feed 10-50 mm/min
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Laser EngravingDescription: Permanent marking via laser ablation. Process Compatibility: Post-processing laser systems Materials: Metals, plastics, wood Key Use: Serial numbers, branding on industrial parts.
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OvermoldingDescription: Molding soft material (TPU/silicone) over rigid inserts. Process Compatibility: Injection molding Materials: Plastics, metals (as inserts) Key Use: Ergonomic handles, waterproof seals. Process Tolerance: Overmold thickness 1-5 mm±0.2 mm, bond strength ≥5 MPa Process Specifications: Injection pressure >5 MPa, mold temp. 40-80℃
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PolishingDescription: Mirror-like finish via abrasive compounds. Process Compatibility: Manual/robotic buffing Key Use: Medical instruments, luxury fixtures. Process Tolerance: Ra 0.025-0.1 μm, gloss ≥90 GU Process Specifications: Wheel speed 1000-3000 rpm, compound grit 2000-5000
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PassivationDescription: Acid treatment to remove free iron and enhance corrosion resistance. Process Compatibility: Post-cleaning chemical immersion Key Use: Surgical tools, food processing equipment. Process Tolerance: Film thickness 0.001-0.01 μm, salt spray ≥96 hrs Process Specifications: Nitric acid 20-50%, process time 20-60 min
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Powder CoatingDescription: Electrostatic polymer powder cured into durable film. Process Compatibility: Post-cleaning spray and bake Key Use: Outdoor furniture, automotive wheels. Process Tolerance: Coating thickness 60-120 μm±10 μm, ΔE≤1.0 Process Specifications: Voltage 30-90 kV, cure 180-200℃×15 min
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PhosphatingDescription: Phosphate layer for lubrication and paint adhesion. Process Compatibility: Chemical immersion Key Use: Engine components, firearm parts. Process Tolerance: Coating weight 2-5 g/m², crystal size ≤5 μm Process Specifications: Bath pH 2-4, process temp. 40-70℃
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PaintingDescription: Liquid coating for color and protection. Process Compatibility: Spraying/dipping Materials: Metals, plastics Key Use: Consumer electronics, automotive body panels. Process Tolerance: Coating thickness 20-50 μm±5 μm, adhesion ≥3B (ASTM D3359) Process Specifications: Spray pressure 0.3-0.6 MPa, cure 80-120℃×30 min
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Sand blastingDescription: Abrasive jet finish for uniform matte texture. Process Compatibility: Post-machining blasting Materials: Metals, glass, stone Key Use: Architectural facades, engine blocks. Process Tolerance: Ra 1.6-6.3 μm, coverage ≥95% Process Specifications: Grit size 80-120, air pressure 0.4-0.7 MPa
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CNC Machining Project
CNC Machining Project
Upload a CAD file to receive instantly quotes, lead time, and DFM details for your CNC components. Specializing in CNC machining for metals and plastics, we provide adaptive production and shipping solutions to align with your product development needs.
What is Overmolding?How Does Overmolding Work?
Overmolding is a multi-material injection molding process where a substrate (typically rigid plastic or metal) is encapsulated or coated with a second material (often soft elastomer or thermoplastic) to create a single, integrated component. This technique enhances functionality by combining properties like grip, shock absorption, and waterproofing, commonly used in tool handles, medical devices, and consumer electronics.
Substrate Preparation:A base part (e.g., rigid plastic or metal insert) is produced via injection molding, machining, or stamping.
The substrate may undergo surface treatment (e.g., plasma etching) to improve adhesion.
Mold Setup:The substrate is placed into an overmolding mold, which is precision-aligned to ensure proper material flow and bonding.
Material Injection:A secondary material (e.g., TPE, silicone, or urethane) is injected into the mold, enveloping the substrate.Temperature and pressure are tightly controlled to bond materials chemically or mechanically.
Cooling & Ejection:The combined part cools within the mold to solidify the overmolded layer.Ejector pins release the finished component, ready for post-processing.
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CNC MachiningWe specialize in manufacturing custom prototypes and end-use parts with precise and complex designs through CNC milling,CNC turning, and CNC precision machining. -
Sheet Metal FabricationWe expert in the flexible manufacture of sheet metal prototypes and precision parts through laser cutting, stamping, metal bending, metal welding, riveting, embossing, flanging and tapping, chamfering and other processes. -
Injection Molding ServicesWorldsoaring provides plastic injection molding, rapid and production tooling, overmolding, and insert molding service. No MOQ required, all while maintaining high-quality and precision molding products. -
More ServicesSLA, HP MJF, SLS, SLM technologies for functional prototyping and low-volume production. We manufacture 3d printed parts at competitive price. -
SolutionsSLA, HP MJF, SLS, SLM technologies for functional prototyping and low-volume production. We manufacture 3d printed parts at competitive price.
Success Stories of Overmolding Projects
FAQs
What is the thickness of the overmolding?
Worldsoaring engineering standards recommend maintaining uniform wall thickness (0.711-3.81mm optimal range) across both substrate and
overmold. This ensures: 1) consistent cycle times by balancing cooling rates, and 2) reliable adhesion through controlled material flow and
shrinkage characteristics in production.
What are the rules for overmolding?
Worldsoaring's decade of injection molding expertise dictates critical overmolding parameters: The overmold thickness must not exceed the substrate's,
and its melt temperature should be 20-30°C lower than the base material. Chemical adhesion is generally ineffective - mechanical interlocking and thermal
compatibility drive successful bonding.
What is the difference between overmolding and 2K molding?
Overmolding traditionally requires transferring a pre-formed substrate to a secondary mold for material encapsulation, creating a mechanical bond.
2K molding (two-shot) accomplishes this in a single cycle using a rotary mold, offering superior efficiency and bond strength. While often used
interchangeably, 2K represents the advanced, single-machine version of overmolding technology.
