Custom Overmolding Services

Overmolding is a precision injection molding process that bonds a secondary material (typically a flexible elastomer like TPE or silicone) over a rigid substrate (plastic or metal) in a single manufacturing cycle, creating an integrated multi-material component.

Common substrate materials include ABS, PC, Nylon, and metal inserts. Overmold materials typically consist of TPE, TPU, silicone (LSR), or other engineered elastomers. Material compatibility is validated by LS Manufacturing to ensure optimal bond strength.

Key benefits include enhanced ergonomics (soft-touch grips), improved sealing and waterproofing, increased impact resistance, vibration damping, aesthetic differentiation, and the consolidation of multiple parts into one integrated assembly.

We ensure adhesion through scientific material selection, substrate surface preparation (texturing, plasma treatment), precise temperature and pressure control during molding, and rigorous bond strength testing (peel tests, environmental aging).

Yes. Overmolding can create permanent, watertight seals (up to IP68/IP69K) by bonding elastomers directly to rigid housings, eliminating the need for separate gaskets. This is ideal for consumer electronics, automotive sensors, and outdoor equipment.

Prototype lead times range from 2–4 weeks, depending on complexity. Production lead times typically range from 4–8 weeks, including mold fabrication, sampling, and qualification. Expedited options are available.

Overmolding is widely used in medical devices, consumer electronics, automotive interiors, industrial tools, and wearables—any application requiring enhanced durability, user comfort, sealing, or aesthetic refinement.

Our quality system includes material compatibility testing, in-process monitoring of molding parameters, 100% visual inspection, bond strength validation (peel/adhesion tests), dimensional verification via CMM, and environmental resistance testing.

Yes. We regularly combine these processes to encapsulate metal inserts, connectors, or electronic components within an overmolded elastomer layer, providing environmental protection, strain relief, and enhanced usability in a single operation.

Cost depends on part size, material combination, volume, and tooling complexity. While tooling costs are higher than single-shot molding, overmolding reduces assembly labor, part count, and improves product value—delivering strong ROI, especially at medium to high volumes.