Precision-Molded Solutions for High-Performance Components
At Davantech, we specialize in overmolding and insert molding services designed to improve the durability, performance, and aesthetic of electronic and mechanical components. With years of engineering expertise and advanced molding technology, we deliver customized solutions for clients across industries—from automotive to industrial automation and consumer electronics.
What is Overmolding?
Overmolding is a multi-step injection molding process where one material—typically a thermoplastic or elastomer—is molded over another component or substrate. This technique creates a single, unified part with enhanced functionality, protection, and appearance.
The base component (insert) can be made of:
- Metal
- Plastic
- Electronics (such as PCBs or sensors)
The overmolded material is carefully selected to provide benefits such as:
- Waterproofing & sealing
- Shock & vibration resistance
- Improved grip and ergonomics
- Electrical insulation
- Strain relief
Download Davantech’s Overmolding and insert Molding Capabilities Overview here
Our Overmolding/Insert Molding Services:
- Connectors: Overmolded electric cables with connectors
- Grommets: Molding grommets and strain relief to electric cables
- Cable splits: Encapsulating split cables
- Insert molding metal contacts
- Molding magnetic connectors
- Insert molding pogo pins
Electronic PCB overmolding
Printed circuit overmolding is a very specific process. It requires experience and the right equipment.
Materials used: TPE, TPU, PP
When it comes to electronics, there are many components that can be overmolded. Overmolding is a process where a material is molded over an existing component, providing additional protection and insulation. It can be a great way to improve the durability and functionality of electronic devices. In this article, we will explore which electronic components are commonly overmolded and the benefits of doing so.
1. Cables and Wires
Durability, Strain Relief, and Environmental Protection
Cables and wires are among the most frequently overmolded electronic components. The overmolding process enhances their reliability by providing mechanical protection, environmental sealing, and improved handling characteristics.
Key Benefits:
- Strain Relief: Reduces stress on wire terminations to prevent breakage.
- Environmental Protection: Shields against water, dust, UV exposure, and temperature extremes.
- Shock & Vibration Resistance: Absorbs impact and movement to extend product life.
- Improved Handling: Soft-touch overmold materials improve grip and ergonomics.
Common Materials:
- TPE (Thermoplastic Elastomer)
- TPU (Thermoplastic Polyurethane)
- PP (Polypropylene)
- Silicone
Our overmolded cable assemblies are widely used in industrial equipment, automotive systems, and outdoor electronics.
2. Printed Circuit Boards (PCBs)
Sealed, Ruggedized Electronics for Harsh Environments
Overmolding PCBs offers robust protection for sensitive electronics, particularly in applications where exposure to moisture, dust, or thermal cycling is a concern.
Key Benefits:
- Moisture and Dust Sealing: Prevents corrosion and short circuits.
- Thermal and Mechanical Protection: Shields components from temperature fluctuations and physical stress.
- Enhanced Form Factor: Allows for custom shapes that improve integration and assembly efficiency.
Common Materials:
- LSR (Liquid Silicone Rubber) – for low-temperature, gentle molding
- TPE/TPU – for rugged, flexible encapsulation
We can design custom overmolds for sensor PCBs, control modules, or embedded systems in automotive, industrial, and consumer electronics.
3. Connectors
Custom Connectors for Secure, Long-Lasting Connections
Overmolding connectors ensures reliable performance even in the most demanding environments. It strengthens mechanical interfaces and enhances sealing for long-term durability.
Key Benefits:
- Ingress Protection (IP-rated Sealing): Keeps out water, dust, and contaminants.
- Improved Mechanical Strength: Reinforces connector housings to prevent damage during use or handling.
- Custom Shapes and Keying: Enables ergonomic designs and secure connections.
Common Materials:
- PA66 GF (Glass-Fiber Reinforced Nylon) – Glow Wire Resistant for EV and high-temperature applications
- TPE/TPU – for flexible strain relief and comfort grip designs
We manufacture standard and custom connectors for electric vehicle (EV) charging systems, industrial sensors, and automated systems.
4. Sensors
Sealed and Accurate for Precise Monitoring
Sensors often operate in harsh or variable conditions. Overmolding enhances their durability, protects delicate electronics, and even improves sensing performance through custom encapsulation.
Key Benefits:
- Complete Sealing: Protects against moisture, chemicals, and mechanical impact.
- Improved Accuracy: Custom-molded shapes can enhance sensor responsiveness and reduce interference.
- Thermal and Electrical Isolation: Maintains signal integrity in sensitive systems.
Common Applications:
- Temperature sensors
- Proximity sensors
- Pressure sensors
- Vibration detectors
Overmold Materials:
- TPE, TPU, and Silicone – chosen based on required flexibility, sealing performance, and temperature resistance.
5. Overmolded Metal Components
Precision Bonding of Metal and Plastic in a Single Step
Insert molding is the ideal solution for integrating metal parts into plastic components with strength, alignment, and durability.
Common Use Cases:
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Metal Axles and Shafts: Plastic is molded directly onto the metal for use in assemblies like joystick mechanisms.
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Threaded Inserts: Metal threads are insert-molded into plastic housings for structural fastening.
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Connector Pins and Contacts: Encapsulated in plastic to form ruggedized electrical connectors.
Advantages:
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Fast Assembly: Combines multiple parts into one integrated component.
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High Strength: Achieves strong metal-to-plastic bonding.
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Design Flexibility: Allows precise control of part geometry and functionality.
Insert molding provides a cost-effective and reliable method for creating hybrid components with mechanical and electrical functions in a single part.
Benefits of Overmolding Electronic Components
There are several benefits to overmolding electronic components. These benefits include:
Protection: Overmolding provides protection against environmental factors such as moisture, dust, and heat. This can help to prevent damage to electronic components
Improved Durability: The overmolded material helps to absorb shock, reducing the risk of damage to the electronic components due to impact or vibration. This can improve the overall durability of the electronic device.
Customization: Overmolding allows for custom shapes and designs to be created, improving the fit and function of electronic components.
Aesthetic Appeal: The overmolded material also improves the aesthetic appeal of electronic devices, giving them a more professional and finished look.
Reduced Cost: Overmolding reduces the overall cost of manufacturing electronic devices. By providing protection and durability, electronic devices are less likely to be damaged or break, reducing the need for repairs or replacements.
In conclusion, overmolding is a process that provides protection and durability to electronic components. Cables and wires, printed circuit boards (PCBs), connectors, and sensors are all common electronic components that can be overmolded. With Overmolding we improve the functionality, durability, and aesthetic appeal of electronic devices, while also reducing the overall cost of manufacturing. If you’re looking to improve the durability and functionality of your electronic devices, consider overmolding as a solution.