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White Paper: Design Considerations for Overmolding and Insert Molding

Manufacturers use overmolding—adding an additional layer of resin to a molded part—to create a combination of characteristics that no single material can provide. Overmolded parts can be found in almost any industry, from medical devices to gaskets and seals within assemblies.

However, material selection for overmolding can be complicated, since the substrate and overmold resins must be compatible. Moreover, material selection is not dependent on application alone—the method being used to make the part also makes a difference.

Two-shot molding and pick-n-place molding are the primary methods for overmolding, with the former using a single production mold while the latter uses two. There are several factors that can help decide between two-shot molding and pick-n-place molding, including production volume, prototyping requirements and time to market.

Like overmolding, insert molding involves injecting a resin over another material, but instead of a plastic substrate, the other material is typically metal and the injected material is typically a rigid plastic. The alternative is to insert metal parts by heat staking or ultrasonic welding, but insert molding is more controllable and allows better encapsulation.

This six-page whitepaper covers design considerations for overmolding and insert molding, including:
  • Two-shot vs. Pick-n-Place
  • Chemical vs. Mechanical Bonding
  • Material Selection
  • Range of Applications


Complete the form on this page to download your free white paper. Your download is sponsored by Proto Labs.

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