Skip to content

Exploring Common Materials for Plastic Overmolding Processes

Injection Molding Process

Plastic overmolding is a widely used process in manufacturing, particularly in industries such as automotive, electronics, and consumer goods. It involves molding a plastic material over a pre-formed substrate, creating a single integrated component with enhanced functionality and aesthetics. The choice of materials for overmolding plays a crucial role in achieving desired properties such as strength, flexibility, and adhesion. In this article, we will explore some common materials used in plastic overmolding processes and their characteristics.

Plastic overmolding is a two-step injection molding process where a thermoplastic material is molded over a pre-existing substrate, typically made of metal, plastic, or another material. The substrate, also known as the insert or preform, provides structural support and defines the shape of the final part. During overmolding, the molten plastic material is injected into the mold cavity, forming a bond with the substrate to create a single, integrated component.

The overmolding process involves molding one plastic material over another. This ensures a seamless combination of multiple plastic parts to give a uniform and durable product.

Common Materials for Plastic Overmolding

  1. Thermoplastic Elastomers (TPE): Thermoplastic elastomers are a popular choice for overmolding due to their excellent elasticity, flexibility, and soft-touch feel. TPEs offer good adhesion to a wide range of substrates, making them suitable for applications requiring a seamless bond between the overmold and the substrate. Common types of TPEs used in overmolding include TPU (thermoplastic polyurethane) and TPE-S (styrenic block copolymers).
  2. Thermoplastic Polyurethane (TPU): TPU is known for its outstanding abrasion resistance, tear strength, and chemical resistance. It is often used in overmolding applications where durability and toughness are required, such as in protective covers for electronic devices and grips for hand tools. TPU can bond well with various substrates, including metals, plastics, and textiles.
  3. Polyethylene (PE): Polyethylene is a versatile thermoplastic widely used in overmolding applications due to its low cost, ease of processing, and good chemical resistance. It is available in various grades, including high-density polyethylene (HDPE) and low-density polyethylene (LDPE), offering flexibility in design and performance. PE overmolds are commonly used in packaging, automotive components, and household products.

Properties of Common Overmolding Materials

Thermoplastic Elastomers (TPE)– Excellent elasticity and flexibility – Soft-touch feel- Good adhesion to substrates
Thermoplastic Polyurethane (TPU)– Outstanding abrasion resistance – High tear strength – Chemical resistance – Bonding capability with various substrates
Polyethylene (PE)– Low cost – Easy processing – Good chemical resistance – Available in various grades for flexibility in design and performance

Top 3 Applications of Overmolding Materials

The injection overmolding process is compatible with a wide variety of materials, ranging from plastics to metals. This process helps produce custom prototypes and production parts for various applications depending on your requirements. Several industries find valuable uses for overmolding services.

  1. Automotive Components: Overmolded TPEs and TPUs are commonly used in automotive applications such as grips, handles, and seals. These materials provide cushioning, vibration damping, and weather resistance, enhancing the performance and comfort of vehicle components.
  2. Consumer Electronics: TPU overmolds are frequently utilized in consumer electronics for protective cases, grips, and buttons. The high abrasion resistance and durability of TPU ensure long-term protection for electronic devices while maintaining a sleek and ergonomic design.
  3. Medical Devices: Medical devices often require overmolded components for ergonomic handles, seals, and connectors. TPEs with biocompatibility and sterilization capabilities are preferred for medical applications to ensure patient safety and regulatory compliance.


In conclusion, the selection of materials plays a critical role in the success of plastic overmolding processes. Thermoplastic elastomers such as TPEs and TPUs offer a balance of flexibility, durability, and adhesion, making them ideal for a wide range of overmolding applications. Polyethylene (PE) provides a cost-effective option for less demanding applications where basic properties such as chemical resistance are sufficient. By understanding the characteristics and applications of common overmolding materials, manufacturers can optimize their designs and processes to meet the diverse needs of various industries.