The overmolding process combines materials to create an entirely new product. It’s one of the most effective and advanced plastic production methods available today.
According to the American Chemistry Council, the US plastics industry creates approximately $371 billion in annual revenue and employs over 673,000 workers. Approximately 26% of the overall manufacturing industry is supported by plastic production.
The material appears in so many essential products that the focus should shift from getting rid of it to making it more efficiently and with less waste. Overloading is a step in that direction.
What is the Overmolding Process?
Overmolding is one of the more advanced molding techniques. It’s a two-step process that creates one part out of two by molding one material over another.
A first layer, known as a substrate, is made first. Then, the second material is injected over or around it.
The two materials have to be compatible for the process to work. Otherwise, you risk damaging or deforming the base layer.
Creating a bond between the two materials is also important. It depends on factors such as:
- Chemical compatibility
- Surface texture of the substrate
- Molding conditions
What Are the Benefits of Overmolding?
The overmolding process requires fewer assembly steps. Components are all created at once, resulting in fewer errors. It reduces assembly time and costs.
Overmolding is cost-effective and efficient. The complexity of equipment setup and mold design can lead to a longer startup, but the overall savings of time and money are worth it.
Overmolding creates more durable products. It’s essential for protecting key components from wear and tear. The increased durability also helps the parts perform better.
The process can make it easy to add features that make products safer and meet regulations.
At the same time, it also improves grip and comfort. Anything from an automobile interior to a toothbrush can have improved ergonomics using overmolding. Adding soft-touch features makes them even easier to hold for long periods.
Overmolding is also versatile. The options for plastic component innovation are almost endless. It also allows for product customization using multiple colors and textures. That can help businesses stand out in a competitive landscape.
The plastic industry is working towards sustainability, and overmolding can help. Shortening their plastic manufacturing process lowers a business’s carbon footprint. Reducing errors also limits the number of failed products that end up in the landfill.
Applications and Innovations
Almost any business can benefit from overmolding. If they need high-performance plastics, they’re probably already using the process to create them. Examples of these industries include:
- Aerospace
- Military
- Entertainment
- Healthcare
Overmolding can help them stand out by making more effective and attractive products. They can also jump on the latest trends, such as 3D printers and incorporating technology into molds.
Get the Best Overmolded Products Today
The overmolding process bonds two or more materials into one. It’s a time-saving process that can help a wide range of industries make the best possible products.
Nova Stevensville is a tier-two and leading tier-one supplier of plastic components. Our goal is to not only meet but exceed expectations.
We partner with other suppliers to provide individual parts and help implement complete systems. Our strong in-house capabilities streamline the manufacturing and approval process.
Request a quote to see how we can help you with your business needs today.
