Overmolding vs Insert Molding

Gripping of tools used every day is now easy with the introduction of insert molding and overmolding. However, confusion tends to set in when comparing overmolding vs insert molding. It is understandable because the two have similar uses, and they are both types of injection molding.

A closer look will help you realize that the processes and some of their applications differ. There are many benefits of using insert molding and overmolding. In this article, you will learn about the differences between overmolding vs insert molding, the application of each manufacturing process, and their advantages and disadvantages.

What is Insert Molding?

Insert molding is a manufacturing process that involves the addition of parts, especially metal, over the molded parts. It involves the introduction of inserts in injection molding. Manufacturers carry out this process before curing the product and help reduce the processes involved during assembling after molding.

After obtaining the parts to be molded over the product, a secondary layer is obtained after inserting the parts into a mold.

There are two ways to carry out insert injection molding – manual and automated insert molding. In terms of cost, manual insert molding is not as costly as automated insert molding. However, the latter is the best option in terms of consistency. There is a minimization of errors from humans, and efficiency increases with automated insert molding.

The introduction of inserts onto mold cores cast using the manual or automated process leads to the plasticization of plastic pellets after closing the mold halves. Ejection of the pieces from the mold takes place after the plastic’s hardening, followed by the encapsulation of the inserts in the parts.

Examples of application of insert molding include the addition of a plastic layer on top of the metal part of a screwdriver to make a plastic handle.

What is Overmolding?

The overmold meaning is the manufacturing process that involves a seamless combination of numerous materials into a solitary part or item. There are two necessary steps in carrying out the overmolding process. The first step involves molding and curing a substrate that is usually plastic.

The second step involves the direct molding of a layer on the first layer leading to creating one product. A typical example is the overmolding of a toothbrush by forming a basal layer and then another rubber layer to the product. 

The cost of production greatly reduced with overmolding. Some of its components include a rigid plastic base enclosed with a thin, flexible material that resembles rubber. The versatility of the manufacturing process is astounding – useful for various items used at home, such as toothbrushes, razors, and hand tools.

Common Trait: Applications of Insert Molding and Overmolding

Insert molding and Overmolding both can produce various parts in several industries. Despite the overmolding vs insert molding difference (shown in the next part), they have common traits in applications.

The applications of these processes either singly or combined result in the production of different products, including:

Automotive Devices

Both processes help produce numerous automotive components containing both metal and rubber/plastic parts. One of the production processes of a battery includes insert molding. Other devices produced with insert molding include knobs, dash panels, motors, and handles.

Cosmetics Industry

The cosmetics industry is another sphere of life that insert molding and overmolding cut across. The insert molding and overmolding produce much of the equipment used in beautifying and enhancing the product’s attractiveness.

These manufacturing processes made creating custom packages with multiple colors and special surface textures possible. Examples of such products include perfume bottles, makeup brushes, and compacts.

Consumer Goods

As stated earlier, insert molding and overmolding are not limited to medical industries and automotive plastic parts production, but it also finds applications in various homes. Many of the materials used at home undergo these manufacturing processes.

These materials include toothbrushes, containers, and cell phone cases. Patio chairs and step stools undergo the process of overmolding before it is safe to use. Whenever you notice solid materials that contain numerous colors at home, they must have undergone one of these processes.

Electrical Appliances

The placing of rubber on top of the electrical wire is possible by the process of insert molding. Coating many products with insulators prevents them from conducting electricity through another body when in contact. Insert modeling makes this possible, and it is safer to handle electrical appliances.

Insert molding and overmolding, the sub-processes of injection molding, are cost-effective manufacturing solutions to produce prototypes and end-use production parts. RapidDirect has the capability to adequately manufacture these custom products across many industries. The expertise and experience of our technical team ensure that you get the best results at the most competitive pricing from your project. Be it consumer goods, electrical appliances, or automotive devices, you can be sure of the utmost quality.