Overmolding is an injection molding process where plastic is molded over a primary component such as another plastic part, a metal part, an electric cable or a printed circuit board. Overmolding can be done for several reasons, such as improving durability or adding a grip or a handle to a part.
How does overmolding work? Well, the melting temperature of the overmolding plastic is lower than the maximum temperature the over-molded substrate can handle. The process typically requires precision molds.
What are some of the advantages of overmolding?
No Need for Fasteners or Adhesives
First, it eliminates the need for fasteners or adhesives. Screws or glue aren’t needed since two or more parts can be molded together in one shot. Also, this process eliminates manual handling. The simple-yet-effective process helps reduce the overall unit cost.
Better User Experience
Next, if you want improved ergonomics and a better user experience, overmolding helps. Think of it in a real-life situation: you go to dry your hair in the morning with a hair dryer, and on that plastic hair dryer is a rubber grip on the handle which makes it easier to grip, right? That rubber grip got overmolded onto the plastic hair dryer. With overmolding, colors can vary, and this can make a product look more aesthetically-pleasing to the eye. You could have a red plastic hair dryer with a grey rubber grip on the handle. Overmolding works well for the production of products that need several colors and/or soft grip layers.
More Complex Shapes
Thirdly, overmolding helps create more complex shapes in a single part. It’s a good alternative to CNC milling or having to assemble different parts with fasteners and glue, thereby reducing flexibility in design.
More Desirable End Products
Then, of course, there are the issues of quality and performance. Everyone’s trying to make their products better than the competition. Well, with overmolding, certain things can be done that help make products more desirable. For example, you can use an over molded printed circuit board under water. Metal contact pains can be isolated from one another in a connector, after overmolding.
Other Advantages
Besides improved product performance, reduced manufacturing costs and being able to make custom plastic parts, overmolding offers better shock absorption. Why is this? Well due to the added plastic resin, an overmolded product can have a longer shelf life and improved resistance against physical impacts. When a product’s durability matters, especially in the automotive industry, for example, you want to make sure durability of the material(s) is a top priority. Resins that can help improve shock absorption include rubber, neoprene or silicone. Overmolding can be used for car components such as hoods, door frames and fenders.
Bridgville Plastics of Stevensville, Michigan, can provide overmolding injections for almost any substrate, including metal, rubber, TPE, etc. Overmolding allows you to create another layer on top of an original part or component, so when you want to be able to do this, Bridgville Plastics can “make it so!” Please call Bridgville Plastics at 269-465-6516 for more information or visit this specific page where you can fill out the online form to send a message: