Overmolding

Overmolds are created when two or more different materials are combined into a single part using a plastic injection molding process. Overmolding is typically done to:

• alter the part’s appearance for design, safety or identification
• enhance durability by adding strain relief and decreasing stress on internal components
• fix sealing elements
• improve the appearance of the product
• make the component water resistant
• protect and simplify the product
• reduce the need for rings and seals

Often this includes covering an existing part with an additional material. For example, TPE (Thermoplastic Elastomer) can be molded onto a rigid plastic-coated wire using heat, pressure and liquid silicon to seal the parts connectors.

Functional Reasons for Overmolding

Overmolding can also add required functional elements to a finished part. Depending on the material used for the overmolding, some of the more specific overmolds purposes include:

• adding strain relief
• changing texture or color
• enhancing grip
• improving handling comfort
• improving the look and feel
• sealing connectors onto wire
• streamlining appearance

DECA Manufacturing has equipment to handle your overmolding requirements:

• equipment sized for 10×10 molds
• 30 ton splice mold machine
• vertical injection molder (made specifically for splicing and overmolding)

DECA has access to the materials, tools and expertise to complete the fabrication of the customized products your application requires.  We also acquire the specialized connectors or military spec components required for your finished product. By using DECA to fabricate components which match your specifications you can focus your manufacturing processes and expertise on other work. Simplifying and improving your product designs can also lower overall your production costs.

To complete your overmolding projects we need the following information:

• prints, drawings or schematics
• bill of materials (BOM)
• approved vendor list (AVL)

Testing and quality control

All our products, including wire leads, are tested using the Cirris System to make sure the products function to the required level. Learn more about our commitment to quality and certifications.