Silicone Overmolding
High‑Precision Liquid Silicone Rubber Molding for Medical, Automotive, Electronics & More.
How It Works – Our Silicone Overmolding
Overmolding is a two-material molding process to mold silicone or LSR over top of another substrate.The substrate could be made from various materials such as silicone,plastic,metal ,fabric,FPC,magnet etc .Overmolding is a two-step process.First,the base substrate is molded.Then the silicone or LSR is molded directly over of the first substrate to create a single integrated part.In a simple conclusion,overmolding bonds a soft, elastic silicone layer onto a rigid part via chemical adhesion during high-temperature curing.
Materials We Work With
Overmolding can be used with a wide range of materials which could stand the molding temperature .
- Silicone (In different color or different hardness)
- High -temperature plastic such as PC, PA (Nylon), PBT, PPSU, PEEK
- Metal such as aluminum,stainless steel
- Magnet
- Fabric
- FPC
- Glass
Why Choose Silicone Overmolding
Overmolding combines one or more materials to create a single integrated part.This process opens up endless possibilities for profile, size and performance customization.It offers numerous advantages.
Flexibility
Durability
Overmolding eliminates bonding step in the manufacturing process,it reduces the risk of coming apart by glue or assembly over time and improve parts reliability.
Cost Efficiency
Overmolding consolidates multi-step into a single manufacturing cycle.It reduces secondary operation for assemblying and needs fewer man-hours.Thus the cost is less .
Applications Across Industries
By combing softness and hardness with multi-material or multi-color ,overmolding is used across many industries .
Medical
Overmolding combines soft and functional silicone material with a rigid substrate like plastic,FPC,metal in a single molded part.This process addresses critical medical requirements for respiratory mask ,surgical handles,Catheter connectors and so on .
Biocompatibility and Safety
Medical-grade silicone material is hypoallergenic, non-toxic, and certified to ISO 10993 (cytotoxicity, sensitization, irritation tests).Overmolding eliminates adhesives or mechanical fasteners, reducing risks of chemical leaching or infection.
Manufacturability and Regulatory
Overmolding combines multiple functions into a single unit .it reduces assembly and minimize loose parts .Single molding process also simplifies regulatory approval compared to mechanically assembled or glued alternatives.
Flexibility and Sterilization
Overmolding enhances design flexibility .Silicone overmolding retains elasticity and adhesion after repeated heat steam .It prevents delamination of microbes .
Automotive
Due to the unique material properties and performance advantange,silicone overmolding is widely adopted in automotive manufacturing like sealing,cover ,connector,etc
Design Flexibility
Overmolding allows silicone to bond seamlessly with rigid substrates (e.g., plastic or metal), enabling integrated, ergonomic designs for buttons, gaskets, handles, and sensor housings.
Lightweighting
Compared to traditional rubber or metal assemblies, silicone overmolding reduces part weight, contributing to fuel efficiency and electric vehicle (EV) range.
Compability
Silicone material could be overmolded onto aluminum, iron, stainless steel ,PA66、PBT、PC or other automotive substrates.It is suitable for whole vehicle ranging from enginer ,interior button to headlights.It meets the reliability test of automotive
Smart Wearing
Silicone overmolding has become a preferred manufacturing process for smart wearables such smartwatches, fitness trackers, smart glasses, brainwave headsets due to its unique combination of comfort, durability, and design flexibility.
Excellent Comfort and Flexibility
Silicone overmolding creates a smooth, soft-touch surface that conforms to body contours. Its low modulus of elasticity and high flexibility allow natural movement, reducing fatigue or pressure points during extended wear.
Skin-friendly and water protection
Overmolded silicone offers skin-friendly contact and durability against sweat and movement.When overmolded silicone onto electronic housing,it provides high ingress protection to ensure device remain functional .
Lightweight and Low Profile
Silicone overmolding adds minimal weight while providing protective and ergonomic layers, contributing to sleek, unobtrusive wearable designs that users forget they’re wearing.
Kitchenware
Silicone overmolding is ideal for kitchenware such as spatulas ,bottle brushes,pot handles,etc due to its unique combination of safety,durability and user-friendly properties .
Comfortable, Ergonomic Grip
Overmolding silicone onto rigid substrates like stainless steel or plastic provides soft, slip-resistant grip areas on kinds of kitchenware handles or grips
It reduces hand fatigues and prevents accidental slips
Impact and Drop Resistance
Silicone overmolding adds a protective, shock-absorbing layer to kitchen tools. For example:The glass lids with silicone edges will resist chipping.The electric housings overmolded with silicone will add impact protection
Aesthetic and Design Flexibility
Overmolding enables manufacturers to create:multi-color designs and seamless transitions between softness by silicone and rigid by plastic or metal .
Related Projects & Case Studies
Frequently Asked Questions
No,not all material is suitable for overmolding processing .The substrate needs to be placed into mold cavity for overmolding .It must stand the mold temperature 120℃at least.
Yes,it works for small MOQ .But overmolding has excessive upfront costs.It is better to produce a large number of parts to distribute the cost .
Yes,self-bonding material is available .Such material chemically adheres to certain engineering plastics and metals without additional primer .
Yes ,we have twice overmolding experience .The first processing is to overmold silicone onto plastic to get the first part,then set magnet on the first part and overmolding another silicone layer
Yes,conductive silicone or conductive liquid silicone rubber could be overmolded onto plastic or metal .
Get in Touch Now
Our service team is 7*24 hours online.
Contact Person: Wendy Huang
WhatsApp:8618950122603