Overmolding
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Custom Overmolding Solutions for a Range of Applications
Our custom overmolding solutions are designed to enhance the functionality, aesthetics, and durability of your parts. Whether you need ergonomic handles, weather-resistant enclosures, or shock-absorbing components.
When you need precision and efficiency, trust us for the best overmolding services. XC Machining delivers high-quality overmolded parts in both small runs and large-scale production
Two-Shot Molding Experts for Multi-Material Components
XC Machining’s plastic overmolding manufacturing services provide high-performance molded parts using a wide variety of plastic materials. As two-shot molding experts, we are skilled at combining two distinct materials into a single molded part. This advanced process allows for multi-material components that are stronger, more versatile, and have enhanced functionality.
Tolerances for Overmolding
| Description | Specification |
| Tolerances | |
| Precision Tolerances | Achievable tolerances as tight as +/- 0.002 inches (0.05 mm) |
| Surface Finish | Ra 16 µin (0.4 µm) to Ra 32 µin (0.8 µm) |
| Minimum Wall Thickness | 0.5mm |
| Minimum End Mill Size | 0.5mm |
| Minimum Drill Size | 1mm |
| Maximum Part Size | 300×300×300 mm |
| Minimum Part Size | 10×10×5 mm |
| Production Volume | Prototyping: 1-100 pcs |
| Low Volume: 101-5,000 pcs | |
| High Volume: Above 5,000 pcs | |
| Lead Time | 7-10 business days for most projects. Delivery of simple parts can be as fast as 3 days. |
Why Choose Overmolding with XC Machining?
In our facility, you have a variety of machines for part production, including CNC turning lathes, milling machines, injection molding equipment, state-of-the-art 3D printing technology, and more.
At XC Machining, we try to ensure your choice is not limited, which is why we offer over 60 materials for you to choose from for your prototypes and products.
In-depth service engineers with the knowledge to address your manufacturing inquiries are available from XC Machining. Our engineers are always on the ground to offer valuable advice.
We offer a range of surface treatments and custom finishes on solid metal and plastic parts, including anodizing, spray painting, vapor polishing, sandblasting, silk screening, etc.
Overmolding Surface finishes Techniques
Overmolding is the process of molding a second layer of plastic around a pre-formed component, often for ergonomic or protective purposes.
Sanding smooths the surface of overmolded parts, especially where there’s a seam or excess material, ensuring a uniform finish and a comfortable grip in consumer goods.
Texturing creates a matte or grippy surface on overmolded parts, improving tactile feedback and preventing slipping, commonly applied to tools or ergonomic handles.
Anodizing is applied to metal inserts in overmolded parts to provide corrosion resistance and an aesthetic finish that improves longevity in harsh environments.
Overmolding Surface finishes Techniques
Overmolding is the process of molding a second layer of plastic around a pre-formed component, often for ergonomic or protective purposes.
Sand blasting creates a uniform matte texture on CNC milled parts, reducing visible tool marks and preparing surfaces for additional coatings.
Brushing produces a consistent directional grain on accessible metal surfaces, enhancing the appearance of CNC milled housings, panels, and brackets.
Anodizing forms a protective oxide layer on CNC milled aluminum parts, improving corrosion resistance and providing a range of decorative color options.
Powder coating adds a durable protective finish to suitable CNC milled metal components, offering customizable colors and environmental protection.
Polishing smooths accessible surfaces of CNC milled metal parts, reducing surface roughness and creating a refined satin or reflective appearance.
Electroplating deposits nickel, chrome, zinc, or gold layers onto CNC parts for corrosion resistance, conductivity, and hardened wear surfaces.
Electroplating deposits nickel, chrome, zinc, or gold layers onto CNC parts for corrosion resistance, conductivity, and hardened wear surfaces.
Electroplating deposits nickel, chrome, zinc, or gold layers onto CNC parts for corrosion resistance, conductivity, and hardened wear surfaces.
Our OverMolding Prototype Manufacturing Capabilities
Provides injection molding for prototypes and custom parts, emphasizing expert support, competitive pricing, and faster production cycles.
Get reliable vacuum casting services for high-quality prototypes and production parts at competitive prices. XinCheng offers highly detailed casting parts with consistent quality.
Uses cutting, bending, and forming techniques to produce precision metal components suited for industrial, commercial, and manufacturing applications.
What Plastic Materials Are Available for Overmolding?
XC Machining offers custom overmolding solutions using engineering plastics such as ABS, Nylon, Polycarbonate, POM, and PEEK, subject to material compatibility. Overmolding combines a preformed substrate with an additional molded material to create integrated components with improved grip, protection, sealing, and functionality. Material selection depends on substrate compatibility, bonding performance, processing temperatures, and application requirements.
ABS offers excellent impact resistance, dimensional stability, and a smooth surface finish, making it a practical substrate for overmolded components. It is commonly used for ergonomic tool handles, electronic housings, automotive controls, and consumer products with soft-touch TPE or TPU overmolds.
Nylon provides excellent toughness, wear resistance, and mechanical strength for overmolded industrial components. It is suitable for reinforced handles, automotive connectors, mechanical housings, and functional assemblies requiring durable substrates and compatible protective overmolds.
Polycarbonate offers excellent impact resistance, dimensional stability, and toughness for overmolded components. It is widely used as a rigid substrate for protective electronic housings, handheld devices, instrument covers, and precision assemblies incorporating compatible soft-touch materials.
POM provides excellent dimensional stability, low friction, and wear resistance for precision mechanical components. It can serve as a substrate in specialized overmolding applications, although its low surface energy makes reliable bonding challenging and may require mechanical interlocks or specialized material systems.
PEEK is a high-performance engineering thermoplastic with excellent heat resistance, chemical stability, and mechanical strength. It can be used in specialized overmolding applications involving high-performance substrates and compatible polymers for aerospace, electrical, and industrial components.
PTFE provides exceptional chemical resistance, very low friction, and excellent thermal stability. Its low surface energy makes conventional overmolding adhesion difficult, while standard PTFE is not processed through conventional injection molding. Specialized surface treatments or mechanical retention methods may be required for PTFE-based assemblies.
Specialist Industries
Materials for Overmolding Parts
Stainless Steel, Titanium, Copper Alloys, Tool Steel (via MIM)
Thermoplastics (PP, PE, ABS, PC, Nylon, POM, PS, PMMA, PBT) and Thermosets (Epoxy, Phenolic, Melamine)
Alumina, Zirconia, Silicon Nitride (via CIM)
TPE (TPE-S, TPE-O, TPE-U, TPE-V), TPU, LSR (Silicone)
Bring Your Designs to Life with XC Machining
Experience precision engineering with XC Machining. From detailed prototypes to high-volume production, we’re here to turn your concepts into reality. Contact us today to discuss your project needs!
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Prototyping Manufacturing FAQs
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