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Overmolding and Insert Molding Service

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    /01
     
    High Quality 
    Parts
     
    Owing certified factories, conducting in-process inspections and dimensional verification after production, guarantee the custom molded parts are consistent in quality regardless of the complex shape with high precision.
     
    /02
     
    Fast 
    Lead  Time
     
    With certified domestic factories and a strong supply chain system, we accelerate the product development cycle and bridge the production of your overmolded parts as fast as possible.
     
     
    /03
     
    Engineering
    Support
     
    Working with our experts having 10+ years of experience in the injection molding industry, efficiently complete a turnaround from prototyping to production.
     
     

    What is

    Tooling in Injection Molding?

    what-is-overmolding
    Overmolding is an advanced plastic injection molding technique used to combine two or more thermoplastic materials into a single, unified part. This process begins by injecting the first thermoplastic, known as the substrate, which forms the core structure of the product. A second material, called the overmold, is then injected either around or onto the substrate, bonding with it as the materials cool. The overmolding technique enhances the durability, functionality, and aesthetics of products, commonly used in high-volume production for industries that require high-performance parts, such as automotive, medical devices, and electronics.

    At RapidDirect, we specialize in custom plastic overmolding to boost the functionality and visual appeal of your components. Our expert team and advanced technology deliver seamless bonds between materials, ensuring top-quality results.

    Contact us today for a detailed quote on custom overmolded parts tailored to your needs.
     

    Overmolding Process _____ 

    plastic-over-plastic

    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

    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

    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

    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

    PROTOTYPING

    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

    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

    • As molded

      There is no secondary polishing or grinding, which means that our parts will display marks from the tooling process.

    • SPI Finishes

      Our SPI finishes range from Grade 3 diamond/high polish to 320 stone low polish. The available finishing options 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, and SPI D-3.
    MATERIALS
    Materials for
    Overmolding
    We offer a broad range of thermoplastic and thermoset materials, each selected for its performance characteristics and suitability for different applications.

    Plastics

    • ABS
      ABS is strong, durable, and offers good resistance to heat and impact. It’s preferred for automotive components and consumer goods.

      ABS Beige(Natural)
      ABS Black
      ABS Black Antistatic
      ABS Milky White
      ABS+PC Black
      ABS+PC White
    • PC
      Polycarbonate is extremely durable and has high impact resistance, along with excellent clarity, used for bullet-proof glass and protective gear.

      PC Black
      PC Transparent
      PC White
      PC Yellowish White
      PC+GF30 Black
    • PMMA (Acrylic)
      PMMA, or acrylic, is known for its crystal clarity and weather resistance, making it ideal for outdoor fixtures and display cases.

      PMMA Black
      PMMA Transparent
      PMMA White
    • POM
    • PA (Nylon)
    • PE
    • PEEK
    • PP
    • HDPE
    • HIPS
    • LDPE
    • PBT
    • PPA
    • PAI
    • PET
    • PPS
    • PS
    • PVC
    • PTFE (Teflon)
    • UPE
    • Bakelite
    • FR-4

    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

    insert-molding-vs-overmolding
    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.
    FAQs

    • 1. How does Injection Mold work?

      The process typically involves the following steps:
      1. Clamping: The two halves of the mold, the stationary side, and the moving side are securely closed together under high pressure. This creates a sealed mold cavity.
      2. Injection: Molten material, usually in the form of thermoplastics, is injected into the mold cavity through a injection molding nozzle. The material fills the cavity, taking its shape and conforming to the mold's contours.
      3. Cooling: After the material is injected, it is allowed to cool and solidify within the mold. Cooling time depends on the material and part design.
      4. Ejection: Once the material has solidified, the mold is opened, and the part is ejected using injection molding ejector pins or other mechanisms.
      5. Cycle Repeat: The process is repeated for subsequent parts, allowing for high-volume production.
       

    • 2. What is the life of a plastic mold?

      Sample~1000,000 times

    • 3. What is the commonly used materials in the cavity？

      P20, H13 steel, NAK80, S136, 738H, etc.

    • 4. What are the Applications of Injection Molded Parts and Injection Molding Products?

      Injection molding applications can be found in various industries, including:
      1. Injection Molding Automotive Parts: Interior and exterior injection molding components, injection molded electrical connectors, and under-the-hood parts.
      2. Injection Molded Consumer Products: Household appliances, packaging, toys, and injection molding electronics.
      3. Medical Injection Molding: Injection molding medical devices, disposable items, and diagnostic equipment.
      4. Aerospace Injection Molding: Interior components, connectors, and structural parts.
      5. Industrial Injection Molding: Custom injection molded enclosures, injection molded gears, injection molded knobs, and machinery components.
       

    • 5. When is Injection Molding Used?

      Injection molding is commonly used when:
      1. Large quantities of parts are required.
      2. Complex part geometries need to be achieved.
      3. High precision and tight tolerances are necessary.
      4. Repeatable and consistent part quality is essential.
      5. Cost-effective production is needed for long production runs.
       

    • 6. How to Reduce Injection Mold cost?

      How much does an injection mold cost? It depends on the mold itself, but you can consider the following strategies to reduce injection mold costs :
      1. Simplify the part design to minimize complexity and tooling requirements.
      2. Optimize the injection mold design for easier manufacturing and reduced material waste.
      3. Collaborate with experienced mold designers and manufacturers who can suggest cost-saving solutions.
      4. Utilize cost-effective materials that meet the required specifications.
       
    Try RapidDirect
    now, for free
    U-Need Precision Machinery Co., Ltd.
      +86 0769 23225585
     +86 15916761371
      contact@uneedpm.com
      Room 401-1, Building 4, SongHuZhiGu Research Center, No.6 Minfu Road, Liaobu Town, Dongguan City, Guangdong Province, China
    523425

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