Overmolding Service
High-quality custom overmolding services for both prototypes and on-demand production parts, with rapid tooling production in as fast as 2 weeks.
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What is Overmolding?
The overmolding process involves molding one plastic material over another, creating a seamless combination of multiple plastic parts into a uniform and durable product. Insert molding and multi-shot molding techniques are employed to combine materials for both functional and aesthetic enhancements. RapidDirect’s plastic injection overmolding utilizes these processes to ensure every component meets industrial standards.
Overmolding Process
Plastic over Plastic
Crucial for mass production, this process involves machining and assembling durable molds from steel or aluminum to ensure precise and repeatable part geometries.
Rubber Over Plastic
Overmolding enhances product functionality and aesthetics by combining different materials into a single part, adding features such as soft grips and multi-color designs for improved usability.
Plastic Over Metal
Insert molding enhances strength and reduces assembly time by integrating metal or other materials directly into plastic parts during the molding process, creating components with embedded features.
Rubber Over Metal
Insert molding integrates metal or other materials into plastic parts during the molding process, enhancing component strength and reducing assembly time by incorporating embedded features directly into the design.
Overmolding Tooling Solutions
PROTOTYPING
Rapid Tooling
Quickly receive design feedback and validation with top-quality prototype tooling. Produce small batches of plastic molded parts with precise injection molding prototypes. We specialize in creating prototype molds within days, allowing you to conduct functional tests and gauge market interest efficiently.
PRODUCTION
Production Tooling
We craft high-quality production molds designed for high-volume plastic part manufacturing. Using robust, durable tool steel, our production tooling is built to produce hundreds of thousands of parts. We can customize materials and construction methods to meet your specific needs.
materials
Materials for Overmolding
We provide a wide selection of thermoplastic and thermoset materials, carefully chosen for their specific performance characteristics to suit various applications.
Plastics
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
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, 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 is strong, with a low friction surface and good dimensional stability, perfect for precision parts in mechanical applications.
- Dark brown (coffee) POM 100AF
- POM Black
- POM Blue
- POM White
Nylon is versatile, strong, and wears well against friction, commonly used for gears, bearings, and other wear-resistant surfaces.
- PA(Nylon) Blue
- PA6 (Nylon)+GF15 Black
- PA6 (Nylon)+GF30 Black
- PA66 (Nylon) Beige(Natural)
- PA66 (Nylon) Black
Polyethylene is lightweight and has high resistance to impact, widely used in packaging and containers.
- PE Black
- PE White
PEEK is renowned for its high temperature resistance and strength, often used in aerospace and medical implant manufacturing.
- PEEK Beige(Natural)
- PEEK Black
Polypropylene is tough, has excellent chemical resistance, and is used for automotive parts, containers, and in packaging.
- PP Black
- PP White
- PP+GF30 Black
HDPE is known for its high strength-to-density ratio, resistance to impacts, and is used in making bottles and corrosion-resistant piping.
- HDPE Black
- HDPE White
HIPS is easy to machine and offers good dimensional stability and impact resistance, suitable for prototyping and modeling.
- HIPS Board White
LDPE is soft, flexible, and used in applications where heat sealing is required, such as in tubing and plastic bags.
- LDPE White
PBT is a strong, rigid plastic that is heat resistant and commonly used in electrical components and casings.
- PBT Black
- PBT Milky White（Natural）
Like High-Performance Plastics, Engineering Plastics, Industrial Plastics, Biocompatible Materials, Food Safe Plastics, and Other Modified Thermoplastics. There are many other plastic or resin materials for different applications. Whether it’s on our material list or not, we could source them from a certified supplier for your project.
Overmolding Capabilities
| 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 significantly enhances product durability and functionality by integrating different materials, providing benefits such as improved grip, aesthetics, and cost-effective assembly.
- Custom Plastic Part Creation: Overmolding enables the creation of custom plastic-plastic or metal-plastic combinations with high dimensional accuracy.
- Enhanced Performance: The two-material approach in overmolding results in superior quality parts tailored for various applications.
- Aesthetic and Shelf Appeal: The process allows for a wide range of materials and surface treatments, enhancing the visual appeal of the product.
- Improved Durability: Overmolding increases shock absorption, leading to longer shelf life and better impact resistance.
- Cost Efficiency: By eliminating the need for post-assembly, overmolding accelerates production and reduces overall manufacturing costs.
Applications of Overmolding
The injection overmolding process is versatile and compatible with a wide variety of materials, including plastics and metals. This flexibility allows for the production of custom prototypes and production parts tailored to specific industry requirements. Various industries benefit from overmolding services:
- Surgical Instruments: Overmolding meets the stringent precision and safety standards of the medical industry. It allows for the efficient creation of surgical devices, equipment housings, catheters, syringes, and more by combining plastics and metals.
- Electrical Applications: The use of thermoplastic elastomers in overmolding is ideal for creating durable electrical components. Custom overmolded parts, such as electrical outlet covers and gaskets, are designed to withstand harsh conditions, enhancing their longevity.
- Hardware Tools: Overmolding is excellent for manufacturing tools like pliers, screwdrivers, hammers, wrenches, and pocket knives. The process improves grip and overall usability, making these tools more efficient in their applications.
- Household Items: Overmolding enhances the functional performance of household items, improving grip, cleanliness, and ease of use. It also provides benefits like vibration dampening and chemical resistance, making it ideal for kitchen utensils, toothbrushes, pens, shampoo bottles, and more.
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