Overmolding

Overmolding is the process of injection molding two or more materials together. This can be done with two different types of material, such as plastic and metal, or it can be done with two different colors of the same type of material.

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 Advantages of Overmolding 

There are a handful of reasons for its preference over the other molding processes. After closely evaluating each one of them, we’ve come up with some of the most impressive advantages of Overmolding for the plastic manufacturing industry.

injection molding surface quality

Performance of parts improved

The overall performance is hence increased because the user has better control of the tool due to the addition of a rubber substrate.

reucing tooling cost

Reduces cost of parts

As this method is a single cycle process, This increases their production rate, and the customers receive the final item faster!

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Excellent shock absorption 

Overmolding is used to provide plastic resins on the product.  the user may feel a reduced shock and vibration when the products is used.

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Elegant structure and design

Elegant structure is a very important factor in product competitiveness, because it immediately catches the eye of the buyers. 

How does Overmolding work?

why injection molding

The overmolding process begins with a mold that has two halves. The first half of the mold is filled with the first material, and the second half is filled with the second material. The two materials are then injected into each other, bonding them together.

The basic items used for Over Molding have been classified into two types – the first one being the substrate, and the second one being the Over Molding material. The substrate may be composed of glass, plastic, metal, or rubber. Whereas the other item is commonly thermoplastic. When these two are combined, their adjoining can be the cause of a mechanical interlock or a chemical bond between the two. Either way, the parts create a new object, for example, scissors, cellphones, drill machines, etc.

Overmolding Vs Insert Molding

Overmolding and insert molding are two injection molding processes that are often confused with each other. Both processes involve injecting material into a mold, but there is a key difference between the two.

Insert molding involves inserting a pre-made piece into a mold before injecting material around it. This is typically done when the piece being inserted is made from a different material than the surrounding material.

Overmolding, on the other hand, involves injecting two different materials into the same mold. The first material forms the base of the product, and the second material is injected on top of it. This allows for a wide variety of design possibilities, as you can create products with multiple colors, textures, and layers.

So, which process is right for you? The answer depends on your specific needs. If you need to create a product with multiple materials, overmolding is the way to go. If you need to insert a pre-made piece into a mold, insert molding is the better option.

Double Injection molding

Application of Overmolding sevices

Overmolding is a popularmanufacturing process, By overmolding, different materials can be glued together to create a variety of shapes, sizes and colors and improve the grip of the product.

Car moldings 

Most automobile companies utilize this process to enhance the appearance of their car. They are installed at the hinges, insides of the door, bumper, and below the windshields.These car trims become easily customized with the help of Over Molding, and that is why every other brand flaunts the difference in their cars. It may create diverse designs, shapes, and colors within and outside the vehicle for superior functioning.

Hardware and Mechanical Tools

Hardware tools have the ability to function on the hardest surfaces, and inaccuracy at any point can result in a fatal injury to the user. When a substrate of rubber or glass material is interlocked around the hardware tool, it becomes easy to handle them as wanted. Not only does it give a better grip on the tool, but also helps to absorb the shocks and vibrations created by them.

Kitchenware & Utensils

The kitchen is one of those places that are used extensively throughout the day. All of them have smooth handles and curved edges to avoid injury and appear extensive. During the process, it is kept in notice that the substrate and the Overmolding material should not affect the food ingredients by any means, and should be safe because it comes in direct contact with hands and the food items.

Typical Household Goods 

Starting right from your toothbrush, extending to the TV remotes, wipers, chargers, shampoo, and deodorant bottles, everything is using Overmolding. We use these items on a regular basis, and seldom do we consider that they are adjoined with various different elements at once to carry out the operations with ease.

Navigation Devices 

With the help of overmolding, the GPS gets to be protected inside a handy structure that has smooth edges and a rigid. Overmolding also prevents the machine from any exposure to harmful elements that could disrupt the proper functioning of this device. The substrate and the thermoplastic are fixed with a mechanical interlocking to keep the body of the device in place.

Medical industry

The tools used widely by doctors, surgeons, and their medical teams are made precisely using Overmolding. Their task is a crucial one and requires apt products that prove to be handy, comfortable, and sustainable. 

For examplexs: Needles, dilators, syringes, injections, patient monitors, scissors, etc.

Materials of Overmolding

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ASB Materials

ABS

Acrylonitrile Butadiene Styrene resin is a milky white solid with a certain degree of toughness, with a density of about 1.04~1.06 g/cm3. It has strong corrosion resistance to acids, alkalis, and salts, and it can also tolerate organic solvents to a certain extent. ABS is a resin that has good mechanical toughness, wide temperature range, good dimensional stability, chemical resistance, electrical insulation properties and it’s easy to manufacture.

  • Common applications: Enclosures
Nylon 6 Materials

Nylon 6

Nylon 6, also known as PA6, polyamide 6, is a polymer compound. Except for its low melting point and wide process temperature range, its chemical and physical properties are very similar to nylon 66. Among all nylon grades, nylon 6 has the lowest modulus.

  • Common applications: Enclosures
Nylon 66

Nylon 66

Polyhexamethylene adipamide, commonly known as nylon-66, is a thermoplastic resin. The performance of nylon 6-6 is better than nylon 6, and the price is not as expensive as nylon 4-6. Its abrasion resistance is the best among all nylons, and its mechanical strength, hardness, and rigidity are very high. Can be used as engineering plastics and making synthetic fibers.

  • Common applications: Enclosures
Nylon 11 Materials

Nylon 11

The density of nylon PA11 is 1.04g/cm3, the melting point is 185℃, the water absorption is 0.1-0.4℅, and the tensile strength is 47-58MPa. It has the advantages of low water absorption, good oil resistance, low-temperature resistance, and easy processing. Widely used in our lives due to its good cost performance.

  • Common applications: Enclosures
PBT Materials

PBT

Polybutylene terephthalate (PBT), a milky white semi-crystalline thermoplastic polyester, is one of the five major engineering plastics. It has high heat resistance. Not resistant to strong acids and alkalis, resistant to organic solvents, flammable, and decomposes at high temperatures. It is widely used in the fields of automobiles, machinery, and equipment, precision instrument parts, etc.

  • Common applications: Enclosures
PC Materials

PC

Polycarbonate is a high molecular weight polymer containing carbonate groups in the molecular chain. It is a tough thermoplastic resin with flame retardancy. Antioxidant. It has excellent impact strength, transparency, and optical properties, mechanical properties, and can be molded to tight tolerances. PC has a wide range of applications, and there are a variety of compounds to choose from.

  • Common applications: Enclosures
PE Materials

PE

The full name is Polyethylene, which is the simplest polymer organic compound and the most widely used polymer material. According to the density, there are 2 types of PE: LDPE and HDPE. It has good inherent lubricity and is easy to process. It should be noted that it is very soft and cannot be used at a temperature much higher than 150.

  • Common applications: Enclosures
PEI Materials

PEI

Polyetherimide (PEI for short) is an amorphous high-temperature super engineering plastic, and its cost is relatively low compared with other high-temperature materials. It has the best high-temperature resistance and dimensional stability, as well as chemical resistance, flame retardancy, electrical properties, high strength, high rigidity, etc. The performance is similar to polycarbonate, but it can work at higher temperatures.

  • Common applications: Enclosures
PE Materials

LDPE

Low-density polyethylene, also known as high-pressure polyethylene (LDPE), is milky white, odorless, odorless, non-toxic, and waxy particles with a matt surface. It has good electrical insulation, transparency, easy processing, and certain air permeability. And has strong extensibility and flexibility, making it have excellent impact strength. This is offset by the permanent deformation after the impact.

  • Common applications: Enclosures
HDPE Materials

HDPE

High-density polyethylene (HDPE) is a white powder or granular product. Non-toxic and odorless, the use temperature can reach 100℃. It does not have the impact strength of LDPE, but it is more elastic. Surface hardness, tensile strength, rigidity, and other mechanical strength are higher than LDPE, close to PP, tougher than PP, but the surface finish is not as good as PP.

  • Common applications: Enclosures
PET Materials

PET

Polyethylene terephthalate (PET), milky white or light yellow, is a highly crystalline polymer with a smooth and shiny surface. It is non-toxic, tasteless, and has good hygiene and safety, and can be directly used for food packaging. It has excellent physical and mechanical properties in a wide temperature range, and the long-term use temperature can reach 120°C. But it is difficult to mold to very close tolerances.

  • Common applications: Enclosures
PP Materials

PP

Polypropylene is abbreviated as PP, which is a colorless, odorless, non-toxic, translucent solid substance. The density is about 0.89~0.91g/cm3, and the operating temperature range is -30~140℃. It is difficult to mold to very close tolerances. Widely used in the production of clothing, medical equipment, automobiles, bicycles, parts, pipelines, chemical containers, etc.

  • Common applications: Enclosures
PPA Materials

PPA

Polyphthalamide is a kind of synthetic resin with high hardness, high strength, good chemical resistance, and low cost. Due to the excellent physical, thermal, and electrical properties of PPA, especially the moderate cost, it has a wide range of applications. Although the use and introduction of PPA are relatively late, its good design data is still very useful.

  • Common applications: Enclosures
PPS Materials

PPS

Polyphenylene Sulfide is a new type of high-performance thermoplastic resin, which has the advantages of high mechanical strength, high-temperature resistance, chemical resistance, flame resistance, good thermal stability, and excellent electrical properties. It is widely used in the fields of electronics, automobiles, machinery, and chemicals.

  • Common applications: Enclosures
PP Materials

PMMA(Acrylic)

PMMA, also known as acrylic, is a tough, highly transparent material with excellent resistance to ultraviolet radiation and weather resistance. It can be colored, shaped, cut, drilled, and shaped. With its beautiful appearance, it has a wide range of applications in the construction industry.

  • Common applications: Enclosures

POM

POM is a crystalline plastic, a density of 1.42g/cm3. It has good rigidity, it is an engineering plastic with excellent comprehensive properties. POM has exhaust problems at high temperatures and is brittle at low temperatures. Glass filled, add lubrication grade available, no flame retardant grade.

  • Common applications: Enclosures
PEEK Materials

PEEK

Peek (polyetheretherketone) is a kind of special engineering plastic with high-temperature resistance, self-lubrication, easy processing, and high mechanical strength, and other excellent properties. It can be manufactured and processed into various mechanical parts, such as automobile gears, oil screens, gear shift start plates; Aircraft engine parts, automatic washing machine runner, medical equipment parts, etc.

  • Common applications: Enclosures
HIPS Materials

HIPS

HIPS(High Impact Polystyrene) is a bright and pure amorphous plastic. It has the advantages of easy processing, rigidity, dimensional stability, and transparency, but its low impact strength limits its application. It has a lower modulus, better elongation, and is much more brittle than crystalline styrene.

  • Common applications: Enclosures
PSU Materials

PSU

PSU is a relatively low-cost high-temperature amorphous material. It is transparent and has good radiation stability and heat resistance. Can be used at temperatures up to 300 degrees Fahrenheit. Widely used in medical equipment, machinery industry, electronic appliances, and other fields.

  • Common applications: Enclosures
PU Materials

PU

PU(Polyurethane) is an extremely elastic, wear-resistant, and tear-resistant elastic material that can be used in ether and ester-based formulations. These different formulations cover a very wide range of hardness and density.

  • Common applications: Enclosures
TPE Materials

TPE

TPE(Thermoplastic Elastomer), also known as artificial rubber or synthetic rubber. It is a kind of elastomer that has the elasticity of rubber at normal temperatures and can be plasticized and molded at high temperatures. It contains thermoplastic and elastomer properties, which makes the product very easy to use in the manufacture of various products. Standard thermoplastic processing equipment and techniques can be used for processing and molding, such as extrusion, injection, blow molding, etc.

  • Common applications: Enclosures
TPU Materials

TPU

Thermoplastic polyurethane (TPU) is an elastic material with good oil resistance, grease resistance, and wear resistance. It is also a mature environmental protection material. It is widely used in medical and health, electronic appliances, industry, and sports.

  • Common applications: Enclosures

Notes On Material Selection

Adhesion

Some materials stick together when they are overmolded, while others do not. Perfect combination is the ideal situation.

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Temperature

Since it is overmolded on plastic, the substrate must not deform under the heat and pressure of the molding process.

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Tensile property

Most materials of overmolding will have several properties related to tensile strength, elongation, tensile modulus, and so on.

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Compression Properties

it may be important for your overmoling project to know how much parts can be compressed without permanent damage.

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Friction coefficient

Friction is the force required to cross one surface over another, The surface texture of the mold is a factor too.

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Hardness

Hardness property is the ability of the material to resist indentation, hardness of different materials vary greatly.

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Flexural properties

The bending resistance of a material is the bending modulus. This attribute is the second factor in the “feel” of materials.

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Thickness

From a design point of view, the thickness of the material will change the effectiveness of the material properties.

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