Overmolding Services

Frigate specializes in overmolding, combining multiple materials for enhanced functionality. Our advanced techniques ensure precise bonding and optimal performance across industries.

Our Clients

Advantages of Overmolding Services

Improved Durability

Overmolding enhances product durability by combining materials with different properties, offering better resistance to wear and environmental conditions.

Enhanced Ergonomics

Overmolding provides soft-touch surfaces, improving grip and comfort in products like handles and reducing user strain during operation.

Cost Efficiency

By integrating multiple functions into a single part, overmolding reduces assembly steps, lowering production costs and minimizing material waste.

Superior Sealing

Overmolding ensures a tight seal between materials, offering enhanced protection against water, dust, and other environmental contaminants.

Enhance Durability and Functionality with Custom Overmolding

Custom overmolding can solve these challenges by combining multiple materials into a seamless component. This process improves product durability, enhances ergonomics, and ensures superior sealing, providing better protection against water, dust, and harsh environments. By reducing the number of components and simplifying assembly, custom overmolding also helps lower production costs. With Frigate’s expertise, you can achieve high-performance, cost-efficient solutions tailored to meet specific industry needs.

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Our Overmolding Process

Material Selection

Choose the base and overmold materials based on desired properties, such as flexibility, strength, and durability.

Mold Design

Create a precise mold with cavities for the base and overmold materials, ensuring accurate material placement.

First Injection

Inject the base material into the mold, forming the core of the part. This material serves as the foundation for the overmolding process.

Preheating (Optional)

In some cases, preheat the base material to ensure optimal adhesion when the overmold material is applied.

Second Injection

Inject the overmolding material into the mold surrounding the base material. The overmold material bonds to the base for improved functionality.

Cooling and Ejection

Allow the part to cool and solidify, then eject it from the mold. The final product combines both materials, offering enhanced performance and durability.

Overmolding Materials

Overmolding combines multiple materials to improve product performance and functionality. It enhances flexibility, durability, and chemical resistance for specific applications.

ABS (Acrylonitrile Butadiene Styrene)

ABS (Acrylonitrile Butadiene Styrene) offers high-impact resistance and dimensional stability. It bonds well with elastomers to create durable, flexible parts used in automotive and electronic housings.

Polycarbonate (PC)

Polycarbonate provides excellent impact strength and heat resistance. Overmolded with elastomers, it’s ideal for automotive housings and electrical connectors, offering high performance under stress.

Thermoplastic Elastomers (TPE)

TPE combines thermoplastic processability with rubber elasticity. It provides flexibility and comfort for soft-touch products commonly used in power tools, medical devices, and electronics.

Polyurethane (PU)

Polyurethane offers high abrasion resistance and tensile strength. It’s used for seals, gaskets, and bushings, especially in industrial and automotive parts, enduring harsh conditions.

Polyethylene (PE)

Polyethylene has excellent chemical resistance and low friction. It’s ideal for overmolding in medical devices, outdoor equipment, and applications needing durability in extreme environments.

Polyamide (Nylon, PA)

Nylon provides high strength and wear resistance. It is often used in overmolding for structural integrity in automotive components and industrial machinery.

Thermoplastic Vulcanizates (TPV)

TPV blends rubber elasticity with thermoplastic processability. It's ideal for seals, gaskets, and vibration damping in automotive and industrial applications.

Silicone Rubber

Silicone offers high-temperature stability and chemical resistance. It’s perfect for overmolding medical devices, food equipment, and automotive engine parts.

Fluoropolymer (PTFE)

PTFE is resistant to high temperatures and chemicals. It’s used in high-performance applications like chemical processing equipment and electrical insulators.

Polypropylene (PP)

Polypropylene is lightweight and chemically resistant. Overmolded with elastomers, it’s ideal for automotive parts requiring a balance of strength and flexibility.

Minimizing Surface Defects for Superior Finish

Surface imperfections like wrinkles, scratches, or tool marks can occur in pneumatic metal forming due to high-pressure contact between the material and the tool. Frigate minimizes these defects by controlling forming pressure, material flow, and tool design. Advanced tooling and process precision reduce surface issues, and secondary processes, such as polishing or grinding, are employed to refine the finish when necessary.

Compliance for Overmolding Services

Overmolding compliance integrates advanced material science, precision engineering, and regulatory adherence. It ensures polymer-metal bonding under complex geometries and extreme conditions. Thermal expansion rates, shrinkage factors, and adhesion properties are tightly controlled. Certifications validate the integrity of critical processes for aerospace, automotive, and medical industries.

ISO 9001:2015

Ensures advanced quality systems for traceable, repeatable processes, minimizing variability in multi-material overmolding.

ISO 13485:2016

Certifies biocompatible overmolding for medical devices, meeting stringent sterility and durability requirements.

RoHS 3 (Directive 2015/863/EU)

Prohibits hazardous substances, ensuring overmolding in electronics meets environmental and health standards.

UL 94 V-0

Regulates chemical exposure in plastics, prohibiting harmful additives and ensuring worker and consumer safety.

FDA CFR 21

Regulates materials for overmolding in direct-contact pharmaceutical and food applications, ensuring safety under operational stress.

ASTM D638-14

Establishes tensile and elongation properties of over-molded materials, optimizing performance under load.

ITAR (22 CFR 120-130)

Mandates secure production controls for overmolded parts in defense and aerospace, preventing unauthorized access.

Tolerance for Overmolding Services

Interface Bond Line Thickness

±0.005 mm

Precise control of bonding layer thickness ensures uniform adhesion and optimal stress distribution.

Gate Vestige Height

≤ 0.10 mm

Minimizes residual material at the gate for improved aesthetics and reduced secondary finishing.

Concentricity

≤ 0.03 mm

Maintains alignment between overmolded features and base components for rotational applications.

Flash Tolerance

≤ 0.025 mm

Controls excess material at parting lines to prevent interference or post-molding cleanup.

Insert Alignment Accuracy

±0.01 mm

Ensures precise positioning of metal or polymer inserts within the overmolded part.

Mold Temperature Control

±1°C

Regulates mold temperature for consistent material flow and dimensional stability.

Cavity Pressure Variance

±5 bar

Monitors pressure consistency to avoid voids or weak bonding in overmolded areas.

Fiber Orientation Deviation

≤ 5%

Controls fiber alignment in reinforced polymers to maintain structural integrity and anisotropic properties.

Surface Finish (Ra)

0.8 µm to 1.6 µm

Achieves specific surface textures critical for sealing, aesthetics, or friction control.

Overmold Layer Thickness

±0.02 mm

Precisely controls layer thickness to achieve desired mechanical and thermal properties.

Cooling Time Variance

±2 seconds

Ensures uniform cooling to minimize warping and maintain dimensional accuracy.

Residual Stress Level

≤ 10 MPa

Limits internal stresses within the overmolded part to prevent deformation or premature failure.

Thermal Expansion Match

≤ 0.05%

Controls mismatches in thermal expansion between materials to prevent delamination under thermal cycling.

Quality Testing Standards for Overmolding Services

Thermal Conductivity

Laser Flash Analysis (ASTM E1461)

Measures heat transfer efficiency through overmold materials for thermal management in electronic parts.

Melt Flow Behavior

Rheometry (Capillary or Rotational)

Evaluates polymer flow properties during molding to optimize processing conditions and prevent defects.

Void Detection

X-ray Computed Tomography (CT Scanning)

Identifies internal voids or inconsistencies within the overmolded component without destructive testing.

Stress Cracking Resistance

Environmental Stress Cracking (ESC) Test

Tests susceptibility to cracking under combined stress and chemical exposure for long-term durability.

Vibration Resistance

Dynamic Mechanical Analysis (DMA)

Assesses the ability of overmolded parts to endure vibrational forces in automotive or aerospace environments.

Dielectric Constant

Impedance Analyzer (ASTM D150)

Determines electrical insulating properties of overmold materials under various frequencies and voltages.

Thermal Expansion Coefficient

Dilatometry (ASTM E831)

Measures expansion rates of overmold materials to ensure compatibility with substrate during thermal cycling.

Gas Permeability

Permeation Testing (ASTM D1434)

Tests the resistance of overmold materials to gas transmission for applications like sealed electronics.

UV Stability

Accelerated Weathering Test (ASTM G154)

Assesses material resistance to UV radiation to prevent degradation in outdoor applications.

Fatigue Resistance

Cyclic Load Testing

Evaluates performance under repeated stress to predict long-term reliability of overmolded components.

Heat Deflection Temperature

HDT Testing (ASTM D648)

Determines temperature at which overmold materials deform under a specified load.

Weld Line Strength

Tensile Testing across Weld Lines

Verifies mechanical integrity at weld lines formed during molding processes.

Gas Trapping

Gas Flow Analysis

Detects and mitigates gas entrapment during molding, ensuring part consistency and adhesion quality.

Substrate Compatibility

Adhesion Mapping via Atomic Force Microscopy (AFM)

Evaluates molecular-level bonding uniformity between overmold and substrate materials.

Streamlining Production of High-Performance Medical Parts

Medical component manufacturers often face challenges in achieving the perfect balance between durability, comfort, and functionality. Overmolding addresses these issues by combining rigid substrates with soft, biocompatible materials in a single part. This technique ensures superior grip, enhanced ergonomics, and reduced need for additional assembly. It also improves component durability, providing resistance to wear, chemicals, and environmental stress. Overmolding allows for more compact, efficient designs, increasing the reliability of medical devices and instruments.

Industries We Serve

What You Get

Managing Material Springback for Precise Dimensions

Springback occurs when materials partially return to their original shape after forming due to internal elasticity. Frigate addresses this by predicting springback during design and using simulations to adjust forming parameters accordingly. Real-time monitoring of pressure and temperature further reduces springback. If deviations occur, precise rework or secondary processes are applied to meet the required tolerances and ensure high precision.

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What Our Customers Say about Frigate

I would strongly recommend Frigate to anyone who wants to do Rapid Prototyping, and 3D Printing and take their ideas to manufacturing. One firm doing all kinds of Product Development!

Thank you so much for your great support so far. Overall, the sheet metal work of the Plotbot Pro was done in an awesome way.Special Mention: The powder coat looks cooler!

The next disruption is happening in Prototyping & Manufacturing on-demand and Frigate is leading the way!I personally believe the Frigate's way of IIOT enabled cloud platform with Al.

I am absolutely happy to work with supplier like Frigate who were quite proactive & result oriented . Frigate has high willingness team who has strong know how & their passion towards the products & process were absolutely thrilling.

Working with Frigate has been great. Their proactive, results-driven approach and expertise shine through in every project. It's been a pleasure collaborating with them.

Having Doubts? Our FAQ

Check all our Frequently Asked Question

How does overmolding improve the bonding between different materials in a single component?

Overmolding uses precise injection techniques to fuse materials with different properties, ensuring strong adhesion. The process ensures seamless integration, minimizing the risk of delamination and increasing overall part strength.

Can overmolding be used for complex geometries without compromising structural integrity?

Yes, overmolding allows for creating complex shapes while maintaining structural integrity. The multi-material injection process ensures that the base material’s strength is preserved, even with intricate designs.

How does overmolding impact the durability and lifespan of molded components?

Overmolding improves durability by combining materials that resist wear, chemicals, and environmental stress. The final product gains enhanced resistance to cracking, abrasion, and harsh conditions, extending its lifespan.

What challenges might arise when overmolding materials with significantly different thermal properties?

Overmolding materials with vastly different thermal expansion rates can lead to bonding issues. Precise temperature control during injection and cooling cycles ensures proper material adhesion and prevents warping.

How can overmolding reduce assembly time and cost in production processes?

Overmolding eliminates additional assembly steps by combining materials into one part. This streamlined process reduces labor costs, assembly time, and the risk of errors associated with multi-component assemblies.

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LOCATIONS

Global Sales Office

818, Preakness lane, Coppell, Texas, USA – 75019

Registered Office

23, 6th West Street, Balaji Nagar, Kattur, Pappakuruchi, Tiruchirappalli-620019, Tamil Nadu, India.

Operations Office

9/1, Poonthottam Nagar, Ramanandha Nagar, Saravanampatti, Coimbatore-641035, Tamil Nadu, India. ㅤ