Overmolding. Seamless Multi-Material Fusion.
We transform standard components into high-performance hybrid systems. Our overmolding technology eliminates the need for adhesives and fasteners, creating a monolithic bond between rigid structures and functional soft-touch surfaces.
[ Chemical & Mechanical Bonding ] [ Precision Shuttle Presses ] [ High-Tactile Finishes ]
Why Partner with REBAN?
The Strategic Advantage of Material Synergy
- Regional Tooling Excellence: Our facility is situated in the world’s most dense tooling cluster. We utilize local expertise in high-precision shut-off design to ensure that multi-material parts have perfect cosmetic seams.
- Cost-Efficient Assembly: By overmolding gaskets, grips, and seals directly onto the part, we eliminate the need for O-rings, glue, and manual labor. This reduces the total bill of materials (BOM) and risk of assembly failure.
- Vibration & Shock Protection: Our overmolding solutions are engineered for rugged environments. The secondary layer acts as a shock absorber, protecting internal electronics in handheld devices and industrial equipment.
- Enhanced Tactile Value: We help you select materials that provide the right “Shore Hardness” (durometer) to match the expected user experience, from ultra-soft medical grips to tough industrial bumpers.
Empowering your agency
Overmolding Engineering Guidelines
Our technical constraints for overmolding are engineered to maximize bond integrity, aesthetic precision, and production velocity. By utilizing high-capacity vertical and horizontal molding cells, REBAN supports expansive part envelopes and tighter tolerances that exceed industry standard prototyping benchmarks.
| Technical Parameter | Metric Standard | Imperial Standard |
|---|---|---|
| Maximum Part Envelope | 850mm x 600mm x 250mm | 33.4 in. x 23.6 in. x 9.8 in. |
| Max Injection Volume (2nd Shot) | 1,850,000 mm³ | 112.9 cu. in. |
| Draw Depth (from Parting Line) | 150mm (Single-side) | 300mm (Total) | 5.9 in. (Single) | 11.8 in. (Total) |
| Max Projected Area (Thermoplastic) | 225,000 mm² | 348.7 sq. in. |
| Max Projected Area (Silicone/LSR) | 65,000 mm² | 100.7 sq. in. |
| Minimum Shot Volume | 45.50 mm³ | 0.028 cu. in. |
| Clamping Force Range | 35 Tons – 1200 Tons | 35 Tons – 1200 Tons |
Overmolding Material Bonding Compatibility Guide
At REBAN, we specialize in achieving high-tenacity fusion between rigid substrates and flexible overmolds. While chemical bonding is achievable across many resin pairs, we utilize a combination of thermal optimization and mechanical interlocking (such as undercuts) to guarantee life-of-product durability.
| Overmold Material | ABS (Industrial) | ABS/PC Blends | PC (Lexan/Optic) | PBT (Valox) | PA66 (Nylon) | PP (Profax) |
|---|---|---|---|---|---|---|
| TPU (Texin/Desmopan) | C | C | C | C | C | M |
| TPV (Santoprene 101) | M | M | M | M | M | C |
| TPE (Santoprene 64) | M | M | M | M | M | C |
| LSR (Elastosil) | – | – | M | M | M | – |
| TPC (Hytrel 3078) | C | C | C | C | C | M |
| TPE (Versaflex OM) | C | C | C | M | M | M |
M = mechanical bond (recommended) C = chemical bond
Understanding the Overmolding Process
Overmolding is a multi-stage injection process that fuses a secondary material over a primary base component, known as the substrate. This sequential method ensures maximum precision and structural integrity.
- Substrate Production: Base parts are manufactured using a standard injection molding process involving aluminum tooling engineered without internal heating or cooling lines.
- Scientific Validation: Controlled, slightly longer cycle times allow technicians to rigorously monitor fill pressures, cosmetic concerns, and basic part quality.
- Precision Encapsulation: Once the substrate run is complete, overmold tooling is assembled to the press, and substrates are placed into the mold by hand.
- Unified Bonding: A secondary layer of either thermoplastic or liquid silicone rubber (LSR) is injected over the substrate to create a permanent, unified component.
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.
Tactile Comfort. Industrial Strength.
Whether you are looking to add a splash of color or a critical waterproof seal, REBAN provides the overmolding expertise to elevate your product.
