Advantages of overmolding

Do you want to know the advantages of overmolding ?

To explain the advantages of overmolding we first explain the overmolding process.

Overmolding is an injection molding process, where plastic is molded over a primary component. That primary component can be one of the following :

  • Another plastic part.
  • An electric cable.
  • A metal part.
  • Or a printed circuit board.

One of the main rules is that melting temperature of the overmolding plastic is lower that the maximum temperature the over-molded substrate can handle. Else the overmolded item is damaged or destroyed. For example, PC cannot be molded to ABS. The reason is that the melting temperature of ABS is lower than for PC.

Overmolding often requires precision molds. In addition the Overmolding can happen in several steps which makes the investment higher. However, the cost will be won back with the advantages obtained by this manufacturing process.

Advantages of overmolding

Eliminating of fasteners and adhesives.

We mold two or more components together in a single or multiple molding shots. There is no need to use screws, or glue.

Reduced assembly cost – reduced part cost.

Just as told in the remark above, a single operator assembles the product during the molding process. The process is repetitive and as such eliminates mistakes which could occur during manual assembly. In addition, the molding  process eliminates manual handling and reduces the overall unit cost.

Improving ergonomics and user experience.

Just think about rubber grip layers on a handle, a hair dryer or other devices. Or the outer shell of a connector. Two-shot molding and co-injection molding are different manufacturing processes. This process is the perfect solution for the production of multi colored products and soft grip layers.

Flexibility in Design.

Where the use of CNC milling or assembly of different parts with fasteners and glue reduces the flexibility, Overmolding gives us the ability to create different, more complex shapes in a single part.

Enhanced quality and performance.

It is possible to use an overmolded printed circuit board under water. But also metal contact pins are isolated from each other in a connector, after overmolding.

overmolding of printed circuit board at Davantech
overmolded seal on a polypropylene flange