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 Bilichitech, 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.

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

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.