Medical/Pharmaceutical
We can add ergonomic features to medical instruments or devices. As well as aesthetic and identifying features on products.
Military/Defense
Overmolding serves to create ergonomic grips and protective touchpoints on dials, instruments, and other field equipment where enhanced usability and durability are required.
Industrial/OEM
We can incorporate ergonomic features into medical instruments and devices through overmolding, while also adding aesthetic and identifying elements to various products. Fuming provides these specialized solutions to enhance both functionality and design.
Injection Overmolding Services – Fuming
Fuming provides comprehensive in-house overmolding services, offering a broad selection of high-quality solutions for all your injection molded part manufacturing requirements. Plastic injection overmolding involves molding new material around or over existing plastic molded forms. This process enables different materials and shapes to be seamlessly combined without requiring separate assembly operations. This injection molding technique is particularly valuable for producing complex components and offers unique properties that may benefit your specific project. Overmolding is a well-established injection molding process in the industry. Our team leverages over 22 years of injection molding experience to provide expert guidance, helping make your products competitive in the market.
Get an online quote for custom overmolding services
Need truly custom overmolded parts? You’ve come to the right place. Fuming delivers high-quality, on-demand injection molding for both prototypes and production components.
Regardless of your experience level, we specialize in complex projects—including those requiring side action or hand-loaded inserts. Our goal is to provide a long-term overmolding solution that extends beyond rapid prototyping, with dedicated project managers and engineering experts guiding you through every stage from design to production. Upload your part to receive an online quote.
Our Capabilities
- Designing for manufacturability
- Developing out-of-the-box solutions to address specific customer requirements
- Providing innovative solutions to solve complex injection molding challenges across medical, electronics, defense, aerospace, and automotive industries
- Ensuring rapid turnaround times and prompt responses to customer inquiries
- Implementing rigorous material management and quality assurance protocols
- Maintaining organization-wide commitment to quality standards
- Upholding a safe and secure work environment
Design considerations
Discover how to maximize the potential of your overmolding project by considering key injection molding design factors, including tooling specifications, material and color options, and finishing and post-processing capabilities.
Overmolding general process information
| Substrate wall thickness | The wall thickness of the substrate directly influences how effectively the overmold material flows onto, into, and around the base component. Temperature variations between the substrate and overmold materials mean that inconsistent wall thickness can result in warping, increased flash, and incomplete fills. Ensure both the substrate wall thickness and overmold layer remain uniform and consistent throughout the process. Maintaining wall thicknesses between 0.060″ and 0.120″ (1.5 mm–3 mm) will promote strong bonding in most overmolding applications. |
| Maximum part size | 800 x 800 x 400 mm 31.5 x 31.5 x 15.7 in |
| Minimum part size | 1 x 1 x 1 mm 0.04 x 0.04 x 0.04 in |
| Tolerance | Best achievable tolerance: ±0.001″ (0.025mm) Standard: ±0.005″ (0.127mm) For larger part tolerances please contact a Fast Radius engineer |
| Lead time | As low as 2 weeks for T1 samples After T1 sample approval, lead time for < 10,000 parts is as low as 1 week |
| Tool validation | Standard process is to produce a small set of T1 samples for approval before initiating full production |
| Maximum press size | 1600T |
| Minimum order size | 100 parts and $5000 |
| Set-up fee | $500 per mold per order (applies to sample runs after initial T1 samples or engineering changes) |
Overmolding tooling information
| Rapid tooling | Molds featuring steel cavities and cores, designed for a shot life of 5,000 to 10,000 cycles. Typical machining lead time is 2 weeks. |
| Production tooling | Steel tooling with shot life up to 1 million cycles |
| Multi-cavity or family molds | Multiple identical cavities or a family of parts can be integrated into a single tool, allowing for more parts to be produced per cycle and reducing per-unit costs. |
| Overmolds | This process involves placing preformed components into the mold and molding over them, enabling multi-material injection molding. |
Materials Used for Overmolding
We offer a comprehensive selection of materials for overmolding projects, tailored to the geometry, complexity, and specific requirements of your application. These materials are organized into three primary categories:
Rigid Plastics
- ABS
- Polypropylene
- Polycarbonate
- Acrylic
- Nylon
- POM
- PTFE
- PBT/PBT-PC
- PEEK
- HDPE
- PVC
- PPS
- PI
- PAI
- UPE/UHMW
- PVDF
- ULTEM (PEI)
Request an instant quote for your overmolding project
Supported by decades of expertise in the design, development, manufacturing, and supply of advanced overmolding and tooling solutions.
Overmolding Finishing and Post-Processing
We provide multiple finishing options to complete products manufactured through the overmolding process. You can select from the following based on your application requirements:
Standard Finish
Interior, non-cosmetic finish that follows the geometry of the mold.
SPI Finishes
Range of SPI finishes from Grade 3 diamond / high polish to 320 stone low polish. These Finishing options include SPI A-1, SPI A-2, SPI A-3, SPI B-1, SPI B-2, SPI B-3, SPI C-1, SPI C-2, SPI C-3, SPI D-1, SPI D-2, and SPI D-3.
Threaded Inserts
We can incorporate the most commonly used standard inserts in both UNF and metric sizes into your parts.
As Molded
This finish option leaves the mold in its original state, as produced, without any secondary texturing or polishing.
Mold Texturing
This finishing option involves creating textures directly on the molds, which are then transferred to the final product. Available finishes include matte, swirls, patterns, and lines.
Laser Engraving
Add part numbers, logos, designs, or other specified markings onto your components through engraving.
Pad Printing
Application of an ink-based design to the surface.
Painting
Surface painting available in standard colors or Pantone matching, including primer and topcoat application. Masking services offered; EMI (copper) conductive coating also available.
Plastic Overmolding Gallery
Our Overmolding Service for Various Industries
Fuming collaborates with leading manufacturers across diverse industries to address growing demands and streamline supply chain operations. The digitalization of our custom injection molding services helps an increasing number of manufacturers bring their ideas to life as finished products.