OverMolding
Advanced Overmolding Solutions for Durable, Multi-Material Parts
At NetProto, we provide expert overmolding services to seamlessly combine multiple materials into a single, high-performance part. Our state-of-the-art facilities and engineering expertise ensure precision, durability, and cost-efficiency for both prototypes and production runs.
What is Overmolding?
Overmolding is a two-step injection molding process that involves molding a soft thermoplastic or elastomer layer (like TPE, TPU, or silicone) over a rigid base component. This technique creates durable, multi-material parts that are both functional and visually appealing.
Key Advantages of Overmolding:
Improved Grip and Comfort: Ideal for handheld tools, medical devices, and ergonomic products.
Enhanced Protection: Adds shock absorption, water resistance, and insulation.
Seamless Integration: Combines materials without adhesives for a strong bond.
Cost-Effective: Reduces assembly time and production costs.
Aesthetic Appeal: Delivers custom textures, colors, and finishes.
Our Overmolding Capabilities
Material Expertise:
We work with a variety of materials for both substrates and overmolds:
Rigid Substrates: ABS, Polycarbonate (PC), Nylon, Aluminum, Stainless Steel.
Overmold Materials: TPE, TPU, Silicone, Rubber, and more.
High Precision Manufacturing
Using cutting-edge injection molding machines and rigorous quality control, we ensure:
Consistent adhesion strength.
Tight tolerances and smooth finishes.
Flawless multi-material bonding.
Scalable Production
From small-batch prototypes to high-volume runs, we scale production to meet your exact needs, ensuring both speed and cost-efficiency.
DFM & Engineering Support
Our team provides Design for Manufacturability (DFM) feedback to optimize part design, reduce costs, and improve performance.
Why Use Overmolding?
Overmolding offers a wide range of benefits across industries:
–Enhanced Comfort: Soft-touch grips for ergonomic use.
Improved Protection: Adds insulation, impact resistance, and waterproofing.
-Reduced Assembly Costs: Combines multiple materials in one seamless process.
–Custom Aesthetics: Textures, finishes, and colors for a refined look.
–Strength and Functionality: Creates parts with both rigid structure and flexible features.
Overmolding Design Considerations
To achieve optimal results in overmolding, the following design guidelines should be kept in mind:
Material Compatibility
Ensure the overmold material bonds well with the substrate material. Common pairings include:
Substrates: ABS, Polycarbonate (PC), Nylon, or Metal.
Overmolds: TPE, TPU, Silicone, and Rubber.
Undercuts & Geometry
Minimize complex undercuts to simplify mold design and ensure smooth part ejection.
Wall Thickness
Maintain consistent wall thickness to prevent warping, sink marks, and voids. Overmold thickness should typically be 1.5–3mm.
Draft Angles
Apply a draft angle of 1–3° to assist with easy part removal from the mold.
Bonding Surface
Design sufficient bonding areas between the substrate and overmold for secure adhesion. Smooth surfaces typically offer better bonding results.
Tolerance Considerations
Account for thermal shrinkage and bonding tolerances, as different materials will cool and solidify at varying rates.
By incorporating these considerations early in the design process, you’ll achieve better part performance, reduced production costs, and consistent quality..