Two-Stage Injection Molding: Overmolding PC and TPE with HS Mold

Watch our latest video to see how HS Mold’s two-stage injection molding process can create high-quality parts with a soft touch. Our video provides a step-by-step guide on how to overmold PC and TPE using our advanced technology and equipment. With our expertise in overmolding and commitment to customer satisfaction, you can trust us to deliver high-quality results every time. Don’t miss this opportunity to learn more about how overmolding with HS Mold can benefit your next project!

Click to watch more our project

Effective Tips for Overmolding Design: Achieve Strong Bonding and High-Quality Results

  • Optimal Wall Thickness: Aim for wall thicknesses ranging from 0.060″ to 0.120″ (1.5 mm-3 mm) to ensure excellent bonding between materials.

  • Corner Radii: Maintain a minimum radius of 0.020″ or 0.5mm in corners to minimize localized stresses and enhance overall durability.

  • TPE Section Design: When incorporating thick TPE sections, consider coring them out to mitigate shrinkage issues, reduce part weight, and improve cycle time.

  • Avoid Deep Blind Pockets or Ribs: Steer clear of designs with deep or un-ventable blind pockets or ribs to prevent potential complications during overmolding.

  • Gradual Wall Thickness Transitions: Ensure smooth and gradual transitions between wall thicknesses to minimize problems such as back fills and gas traps, ensuring smooth flow.

  • Substrate Thickness: The TPE/TPV overmold material should be thinner than the substrate to prevent warping, particularly in long or flat parts.

  • Bonding Compatibility: Select overmold materials that offer mechanical or chemical bonding properties to ensure a strong bond with the substrate.

By following these design tips, you can optimize the overmolding process, enhance bonding strength, and achieve high-quality results for your project.

Picture of overmolding plastic parts
Click me to send design for free review

HS Mold Company: Your Trusted China Mold Maker for Custom Plastic Overmolding

HS Mold Company is a leading China mold maker specializing in custom plastic overmolding. Our advanced plastic injection molding process seamlessly combines two thermoplastic materials to create visually appealing and ergonomic parts like handles or knobs.

We work with a wide range of materials, including soft plastics (urethanes, TPE) and hard plastics (nylon, polycarbonate), offering versatility and customization options. Our overmolding techniques not only enhance aesthetics but also strengthen and protect parts while reducing costs and labor.

As a trusted China mold maker, we prioritize customer satisfaction, leveraging cutting-edge technology and industry expertise. Experience the difference with HS Mold Company’s tailored overmolding solutions. Contact us today to unlock the full potential of your plastic parts.


Unlocking the Benefits of Plastic Overmolding with Customization and Cost Efficiency
  1. Cost Efficiency: Overmolding reduces secondary operations, assembly, and labor costs since multiple components are molded as a single assembly. It eliminates the need for bonding, improving component reliability and saving time and money.

  2. Enhanced Strength: Overmolding strengthens parts, providing better structural integrity. Components can withstand vibrations and shocks, ensuring long-lasting performance.

  3. Secure Alignment: Overmolded components have precise alignment, preventing loosening or misalignment during use. This improves functionality and durability.

  4. Design Flexibility: Custom plastic overmolding allows for creative design possibilities. Manufacturers can combine multiple thermoplastic materials, enabling the production of multi-material components with unique properties.

By leveraging the advantages of plastic overmolding, manufacturers can achieve cost savings, improved strength, secure alignment, and design flexibility in their products.

Applications of Overmolding Services:

  1. Medical Devices and Instruments: Overmolding is widely used in the production of medical devices and instruments, providing soft grip handles for surgical tools, ergonomic grips for diagnostic equipment, and comfortable handles for medical instruments.

  2. Soft Grip Handles for Various Parts: Overmolding is utilized to create soft grip handles for a variety of products such as hand tools, power tools, kitchen utensils, and sporting equipment. The added grip enhances user comfort, control, and safety.

  3. Knobs for Appliances, Controls, and Assemblies: Overmolding is employed to manufacture knobs used in appliances, controls, and assemblies. These knobs offer improved ergonomics, functionality, and aesthetics.

  4. Encapsulated Electronic Devices and Electrical Components: Overmolding is utilized to encapsulate electronic devices and electrical components, providing protection against moisture, dust, and mechanical stress. This process ensures reliable performance and extends the lifespan of the components.

In these applications, overmolding offers valuable advantages such as improved ergonomics, enhanced functionality, increased durability, and aesthetic enhancements. By utilizing overmolding services, manufacturers can create high-quality products with added value for various industries.

Pictures of overmolding plastic parts

Latest News

Lorem ipsum dolor sit amet, consectetuer adipiscing elit, sed diam nonummy nibh euismod .

Our blog

ADd a callout header here

Lorem ipsum dolor sit amet, consectetuer adipiscing elit, sed diam nonummy nibh euismod tincidunt ut laoreet dolore magna aliquam erat volutpat.