Overmolding Casting. Advanced Composite Prototyping.
REBAN’s Overmolding Casting process bridges the gap between simple prototypes and complex, multi-material industrial products. By casting secondary elastomers over rigid substrates (metal or plastic), we deliver high-fidelity components with integrated grips, seals, and shock-absorption—replicate the “look and feel” of high-end 2K injection molding at a fraction of the tooling cost.
[ Hybrid Material Bonding ] [ Precision Manual Indexing ] [ Dual-Durometer Synergy ]
Why Partner with REBAN?
The Strategic Advantage of Material Synergy
- Advanced Adhesion Science: We utilize specialized industrial primers and bonding agents to ensure a molecular-level fuse between materials, preventing soft-touch layers from peeling under heavy stress.
- Precision Encapsulation: Our team excels at “insert casting,” seamlessly integrating sensors, threaded bushings, or metal skeletons within the cast to create fully functional, composite units.
- Rapid 2K Bridge Tooling: Validate dual-material ergonomics without the high cost of multi-shot injection molds. We deliver 20–50 “market-ready” units optimized for user testing and crowdfunding.
- Calibrated Tactile Experience: We offer precise “Shore Hardness” (durometer) tuning to match your specific requirements—from “ultra-soft” medical grips to “high-impact” industrial bumpers.
Overmolding Casting Technical Matrix
| Technical Parameter | REBAN Regional Standard | Engineering Notes |
|---|---|---|
| Material Combinations | Rigid (ABS/PC/Metal) + Soft (TPE/PU/Silicone-like) | Optimized for Shore 30A to 90A durometers. |
| Bonding Strength | Chemical Fusion + Mechanical Interlocks | Utilizes primers and undercut designs for permanent anchoring. |
| Shut-off Precision | ±0.2mm on material transition lines | Tight silicone-to-substrate fitment prevents resin “flash.” |
| Insert Capability | Metal Threaded Inserts, Cables, PCBs, Magnets | Ideal for encapsulated electronics and IP67 waterproof seals. |
| Surface Finish | Dual-tone Colors, Soft-touch textures, Non-slip grains | Can replicate MT-11010 or specific ergonomic patterns. |
Design Guidelines for Overmolding Casting (DfM)
- Mechanical Anchors: Always include grooves, holes, or “dovetail” features in your rigid substrate. This provides a physical “lock” for the soft resin, significantly increasing durability.
- Wall Thickness Balance: The overmolded layer should ideally be 1.0mm to 3.0mm thick. Layers thinner than 0.8mm may struggle to flow evenly through the silicone mold under vacuum.
- Shut-off Grooves: Design a small “step” or groove where the two materials meet. This provides a natural break point for the silicone mold, ensuring a clean, flush cosmetic seam.
HOW TO WORK WITH US
Upload a CAD File
To start, simply select a manufacturing process and upload a 3D CAD file.
Get Quote with DFM
Within a few hours we'll send you design for manufacturability (DFM) analysis and real-time pricing.
Manufacturing Begins
Once you review your quote and place your order, we'll start the manufacturing process. We also offer finishing options.
Parts are Shipped!
Our digital manufacturing process allows us to produce parts in as fast as 1 day.