Overmolding & Insert Molding

Our rapid overmolding and insert molding processes produce custom prototypes and on-demand production parts in 15 days or less. We use aluminum molds that offer cost-efficient tooling, and molded parts can be manufactured from a range of thermoplastic and liquid silicone rubber materials.



25 to 10,000+ parts
Shipped in 15 days or less
Molds start at $4,990*

*Cost includes both substrate and overmold tools. Insert molding tools start at $2,495.

Process

Pre-production

With overmolding, the production of the substrate parts is a standard injection molding process involving an aluminum mold with no heating or cooling lines running through it. Cycle times are a bit longer, which allows our molders to monitor fill pressure, cosmetic concerns, and the basic quality of the parts.

When the total run of substrate parts are molded, overmold tooling is then assembled to the press. The substrate parts are placed by hand into mold where each part is overmolded with either a thermoplastic or liquid silicone rubber material.

Insert molding is a similar process but instead uses a preformed part—often metal—that is loaded into a mold where it is then overmolded with plastic to create a final component. When the run is complete, parts (or the initial sample run) are boxed and shipped shortly thereafter.

Production

Resin pellets—from either a stocked or customer supply—are loaded into a barrel where they will eventually be melted, compressed and injected into the substrate mold’s runner system. Hot resin is shot into the mold cavity through the gates and the part is molded. Ejector pins facilitate removal of the part from the mold where it falls into a loading bin.

When the total run of substrate parts are molded, overmold tooling is then assembled to the press. The substrate parts are placed by hand into the mold where each part is overmolded with either a thermoplastic or liquid silicone rubber material. The part is ejected and the pick-n-place process begins again. When the run is complete, parts (or the initial sample run) are boxed and shipped shortly thereafter.

Overmolding Process
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