Top 10 Overmolding Manufacturers in the World

We believe that you would like to purchase your overmolded products from the world’s best overmolding companies. To do so, we need to form the world’s best overmolding companies. In this article, here, we will provide the world’s top 10 overmolding companies and provide a brief overview of their companies and contributions towards precision molding.

1. List of Overmolding Manufacturers in the World

Below is a selectively researched compilation of the world’s top overmolding companies by technical expertise, production capacity, and reliability developed in diversified industries.

2. Top 10 Overmolding Manufacturers in the World

Overmolding is an extremely important manufacturing process that helps to integrate various kinds of materials to produce strong, functional, and cosmetic parts. Here are the world’s best 10 overmolding companies based on their potential, innovative nature, and dedication towards developing high-quality solutions for diversified markets.

Top 1: Holly Plastic Parts

Holly Plastic Parts is a precision multi-shot overmolding firm with over two decades of experience in providing services to the automotive, medical, and consumer electronics industries. Holly Plastic Parts takes up a 15,000-square-meter Dongguan factory with the ability to house over 40 large-volume vertical injection and multi-shot overmolding-compatible machines from world-leading firms. Holly is used in two-material and multi-material overmolding processes, and in co-molding of hard plastic and soft plastic or plastic and metal alloys with the aim of providing consumers with comfort and strength.

They have installed their engineering lab with mold flow analysis, DFM (design for manufacturability), and rapid prototyping, quick-turn. Holly is IATF 16949 certified and ISO 9001 with high-pressure work, rigorous quality control. With tooling in under 15 days and reduced lead times, the company effectively manages low-run as well as high-production runs.

One of the most significant customer examples was the production of overmolded enclosures for a United States medical device company. They required the components to endure repeated use and sterilizations, which Holly met at a 98.7% pass rate on 100,000+. On-the-shelf tooling and post-molding assembly were also accommodated by the customer’s requirement.

Website: https://www.hollyplasticparts.com/overmolding/

Year established: 2000

Location: China

Products:

• Overmolded Housings
• Multi-material Components
• Custom Plastic Parts
• Plastic Injection Molds
• Insert Molding Parts

Top 2: Protolabs

The market leader is Protolabs because it has overmolding capacity that is rapid, scalable, and accurate. Protolabs is based in Maple Plain, Minnesota, USA, and possesses more than 12 factories worldwide and manufactures more than 6 million parts annually. Two-shot and insert molding technologies are used by its overmolding capacity, which works best to manufacture parts with in-mold elastomeric grips, seals, and soft-touch finishes.

They are the leader in auto DFM and online quote checking in the market, and they shorten the lead time from design lead time to production lead time to 1 day. They have less than 15 business days of mold manufacturing lead time and can accept material input from TPU, TPE, LSR, to engineering-grade resin. They are ISO 9001 and ISO 13485 certified and thus an ideal partner to high-precision businesses like aerospace and medical devices.

Amongst the leading projects was the creation of more than 250,000 overmolded cases for a dominant EU wearables company. The company required soft-touch parts with ultra-viz looks and UV stability so they would endure for years. Protolabs produced more than 250,000 units with a lead time of 6 weeks, which allowed the company to realize an under-pressing launch schedule.

Website: https://www.protolabs.com/

Year established: 1999

Location: Maple Plain, Minnesota, USA

Products:

• Overmolded Parts
• Insert Molded Components
• Medical Device Housings
• Custom Plastic Enclosures
• Rapid Tooling

Top 3: LTM Plastics

LTM Plastics is an extremely seasoned US-centered overmolding and specialty plastic injection mold firm with over 45 years of experience. LTM Plastics, with a Denver, Colorado, location, has a 42,000-square-foot facility and over 30 injection mold presses from small 40-ton presses up to large 720-ton presses. LTM is highly recognized for its two-shot molding, insert molding, and overmolding proficiency in a wide variety of industries, including industrial, medical, and electronics.

LTM offers a turn-key facility in secondary assembly, in-house tool design and testing, and packaging. It is ISO 9001:2015 compliant with guaranteed rigorous quality checks and lean manufacturing principles, low waste, and short cycle time, accommodating. It offers small-lot prototype and high-volume manufacturing support and ships molded parts out in four weeks.

One of the spotlight success stories was the manufacture of more than 4 million units of overmolded sensor housing for a farm equipment OEM. The technical challenge was to overmold flexible elastomeric TPU with hard polycarbonate to achieve weather sealing and abrasion resistance. LTM technical support and in-process, real-time quality inspection cut defects to below 1% and allowed the customer to reduce warranty claims by 35% in a year.

Website: https://www.ltmplastics.com/

Year established: 1977

Location: Denver, Colorado, USA

Products:

• Overmolded Sensor Housings
• Insert Molded Parts
• Plastic Enclosures
• Multi-material Components
• Custom Plastic Assemblies
• Injection Mold Tooling

Top 4: EVCO Plastics

EVCO Plastics is a century-old custom injection molder with global facilities offering cutting-edge overmolding technologies to automotive, healthcare, industrial, and consumer electronics customers. EVCO was established in 1964 and maintains its international headquarters in DeForest, Wisconsin. EVCO operates 10 global facilities with a presence across the United States, Mexico, China, and Malaysia. With over 180 injection presses ranging from 28 to 3,500 tons in capacity, the company offers advanced overmolding features like multi-material bonding, insert molding, and liquid silicone rubber (LSR) overmolding.

EVCO’s design group provides total DFM and design assistance, in-mold assembly, automation integration, and secondary processes like ultrasonic welding and in-line inspection. EVCO is certified to ISO 13485 and IATF 16949 to allow customers’ reproducible performance in regulated markets. EVCO tracks real-time production data with its intelligent manufacturing technology, and that results in less than a 0.5% defect rate on millions of units annually.

A case in point is a high-volume specialty application of overmolded handles by a global power tool manufacturer. EVCO produced over 1 million soft-grip handles per annum to produce a uniform cosmetic appearance, feel in the hand, and increased adhesion in abusive end-use environments.

Website: https://www.evcoplastics.com

Year established: 1964

Location: DeForest, Wisconsin, USA

Products:

• Overmolded Tool Grips
• Insert Molded Components
• LSR Molded Parts
• Medical Enclosures
• Automotive Interior Parts
• Multi-material Assemblies

Top 5: PTI Engineered Plastics

PTI is a full-service, world-class overmolding and injection molding company with a plant in Macomb, Michigan, USA. PTI has been a worldwide leader in progressive overmolding solutions for the automotive, medical, aerospace, and defense markets since 1984. PTI operates a 150,000-square-foot facility with over 50 injection molding machines that vary from 35 to 1,100 tons, including prototype and high-rate production capacity.

PTI employs cutting-edge two-shot and insert overmolding technology, historically best explained to join hard substrates to TPEs, TPUs, or silicone to form functional products with greater functionality and consumer comfort requirements. PTI also offers in-tooling, DFM, mold flow simulation, and Class 8 cleanroom molding. PTI is ISO 13485, ISO 9001, and AS9100 certified and a compliant supplier to regulated markets.

One such all-around customer success story is the case of a medical surgical instrument manufacturer company that required a multi-sterilization capable and tolerance high fit overmolded handpiece housing. PTI manufactured more than 300,000 units yearly with rejection levels less than 0.3%, which helped the customer fulfill FDA requirements as well as minimize production downtime.

Website: https://teampti.com/

Year established: 1984

Location: Macomb, Michigan, USA

Products:

• Overmolded Medical Housings
• Insert Molded Assemblies
• Cleanroom Molded Parts
• Surgical Instrument Components
• Automotive Connectors
• Custom Plastic Enclosures

Top 6: Bermar Associates, Inc.

Bermar Associates, Inc. is a global market leader in the delivery of custom overmolding solutions with high-performance application knowledge in medical, industrial, and consumer products markets. Bermar was established in 1969 and has a facility in Danvers, Massachusetts, with a state-of-the-art plant having injection molding as well as overmolding capability. Bermar boasts over 50 years of service history to world markets in manufacturing prototype and high-volume overmolded parts.

Bermar is a leading supplier of overmolding TPEs, silicones, and hard plastic overmolding with guaranteed adhesion and performance in handles, grips, and enclosures. Bermar’s ISO 9001 and ISO 13485 assure repeat quality within highly regulated segments. Bermar works closely with customers on mold design and DFM and is prepared for prompt prototyping service to advance time-to-market.

One of the largest client success stories was Bermar overmolding specialty grips for a medical device company that produces handheld equipment. The firm overmolded more than 1 million grips annually, improving ergonomics, wear life, and grip comfort for medical staff.

Website: https://bermarassociates.com/

Year established: 1969

Location: Danvers, Massachusetts, USA

Products:

• Overmolded Medical Grips
• Custom Plastic Assemblies
• Ergonomic Handles
• Multi-material Components
• Industrial Housings
• Custom Enclosures

Top 7: Norck

Norck is a premier overmolding manufacturer of high-complex injection molding and multi-material solutions for the automotive, medtech, and electronics industries. Norck started production in 2009 and has facilities in California. Norck has a state-of-the-art facility with high-precision injection machines and automation technologies that enable it to offer quality overmolded parts at low costs.

Their overmolding capabilities in-house are insert molding, soft elastomer overmolding on hard plastic, and multi-shot molding for use in strength-critical, flexible, and ergonomic products. Norck provides customers with in-house mold design, DFM checking, prototyping, and downstream activities like assembly and packaging. Their quality is assured with conformity to ISO 9001:2015 standards and conformity to industry standards.

One of their most effective customer success stories was manufacturing overmolded connectors for a global automobile customer. They required the components to be able to withstand harsh vibration and harsh weather conditions. Norck delivered one million units per year with a 98.6% pass rate quality, which enabled the customer to improve the products’ reliability in harsh conditions.

Website: https://www.norck.com/

Year established: 2009

Location: California, USA

Products:

• Overmolded Connectors
• Multi-material Components
• Automotive Parts
• Medical Device Assemblies
• Custom Plastic Housings
• Electronic Enclosures

Top 8: RapidDirect

RapidDirect is a top rapid manufacturing and prototyping company with overmolding facilities in the medical devices, automotive, and electronics sectors. RapidDirect is a 2009-established company with facilities located in Shenzhen, China. RapidDirect is a state-of-the-art facility that owns state-of-the-art high-tech injection molding technology, enabling it to provide fast turnaround and affordable production of high-quality overmolded parts.

They are an overmolding specialist for multi-materials offering insert molding, two-shot molding, and dual elastomer applications like TPE and TPU. Automated online quoting, real-time project tracking, and DFM assistance make RapidDirect services easy for customers to achieve accurate, cost-effective results. Secondary processes like assembly, painting, and ultrasonic welding are also offered by their specialists. With ISO 9001:2015 certification, RapidDirect offers quality assurance and international standard conformance.

Some of their notable projects involve the manufacturing of overmolded parts for one of the world’s largest consumer electronics companies. The company required soft-touch overmolding for handheld units in order to enhance user touch and handling. RapidDirect shipped up to 500,000 pieces in three weeks with fewer than 0.2% defects.

Website: https://www.rapiddirect.com/

Year established: 2009

Location: Shenzhen, Guangdong, China

Products:

• Overmolded Handheld Devices
• Custom Electronic Enclosures
• Consumer Product Parts
• Automotive Components
• Multi-material Assemblies
• Medical Device Housings

Top 9: Elimold

Elimold is an injection molding and overmolding expert with worldwide dominance, that builds innovative, precise solutions for their customers across industries of automobiles, medicine, consumer electronics, and telecommunications. Established operations since 2012, Elimold has its HQ in Shenzhen, China, with an ultra-premium facility of high-grade injection molding equipment and advanced-level automation platforms for serving low-volume or volume production scale requirements.

Elimold is familiar with multi-material overmolding, such as over TPE, TPU, and silicone, for improved tactile feel, hardness, and weathering for those requiring such. Concept-to-finish customer services, mold design and qualification, DFM, rapid turnaround prototyping, and post-molding assembly services are provided by Elimold. Elimold’s quality commitment can be accessed through its ISO 9001 and ISO 13485 certifications as proof of conformity to worldwide manufacturing standards.

A few such projects include overmolding enclosures for a major worldwide telecom solutions provider. Overmolded parts were required with better impact-resistant and UV-stable qualities in this project, and Elimold did it with over 95% on-time delivery and less than 0.3% defect rate.

Website: https://elimold.com/

Year established: 2012

Location: Shenzhen, Guangdong, China

Products:

• Overmolded Electronic Housings
• Custom Enclosures
• Medical Device Components
• Automotive Parts
• Multi-material Assemblies
• Precision Molded Parts

Top 10: Eigen Engineering

Eigen Engineering is a precision engineering solutions company that specializes in overmolding services for high-performance end-applications in the automotive, medical device, and consumer electronics industries. Founded in 2006, Eigen Engineering has its corporate office in Pune, India, and a state-of-the-art manufacturing facility with a complete suite of injection molding technologies such as multi-shot and insert molding. Eigen Engineering has experience in offering cost-effective, high-quality overmolded parts for prototype and volume production.

With the hope of innovating, Eigen Engineering is a committed producer of rigid as well as flexible multi-material parts and hence is ideally suited for applications wherein structural integrity, along with touch functionality, is of primary importance. Eigen Engineering provides total end-to-end service during the product life cycle from material choice and design through mold tooling, rapid prototyping, to post-mold assembly. Eigen Engineering is ISO 9001:2015 certified and uses cutting-edge manufacturing technologies to deliver high-quality and high-efficiency levels.

One such was the production of overmolded components for a leading medical device manufacturer with high accuracy and compliance with medical industry standards. Eigen Engineering was able to produce over 200,000 units annually at a 99.8% on-time delivery rate without any compromise on strict quality checks throughout the process.

Website: https://www.eigenengineering.com/

Year established: 2006

Location: Pune, Maharashtra, India

Products:

• Overmolded Medical Components
• Automotive Parts
• Multi-material Assemblies
• Custom Plastic Housings
• Consumer Electronics Parts
• Precision Molding

3. Strategic Advisement in Choosing Overmolding Suppliers Globally

Choosing the overmolding supplier is a do-or-die decision for your project. To ensure that you’re working with a supplier who will be in a position to meet your manufacturing needs and your technical needs, the following are some strategic advisements:

1) Industry-Specific Experience

Not all overmolding applications are the same. The medical device component part and the automotive part each have a completely different set of requirements. Attempt to locate a manufacturer that has in-house industry experience within your market niche so they have some idea of the unique challenges of your industry, e.g., regulatory requirements, material requirements, and compliance restrictions.

2) High-Level Molding Capacity

Overmolding is not just a pour of plastic into a mold. It involves advanced processes like multi-shot molding, insert molding, and application of specialty materials (i.e., TPE, silicone). Choose a supplier that has state-of-the-art equipment and offers specialty solutions. A supplier that can tailor its process to meet your unique product demands will be able to offer better quality output.

3) Production Flexibility

Low- and high-volume ramp-up production or pre-production of a new concept, flexibility is the key. Ensure that the producer will accept low- and high-volume orders without sacrificing quality or productivity. A supplier capable of offering rapid prototyping, flexible lead times, and variable capacity manufacturing is essential to accommodate project schedules and risk avoidance.

4) End-to-End Support

Find a supplier that can offer end-to-end assistance from design assistance, prototyping, mold design, right up to post-manufacturing processes like assembly or packaging. Being able to do product manufacturability design will reduce errors and keep production running well.

5) Demonstrated Reliability

Last but not least, don’t believe promises blindly—require evidence. Request case studies or references from past customers who’ve undertaken similar projects. A company that has a proven history demonstrated in the provision of challenging, high-value overmolding solutions is more likely to deliver on its promise.

By considering these aspects—industry knowledge, technology lead, flexible manufacturing, single-source, and proven reliability—you can confidently decide between overmolding companies that can deliver your dream in the right manner with accuracy and efficiency.

4. Conclusion

The above 10 overmolding companies are the best of the best of the overmolding industry, each one of them having proven high innovation and experience at their company. With the most recent manufacturing plants, product lines diversified and excellence-driven, they keep pushing the envelope for overmolding uses in as broad a range of industries as automotive, medical, to electronics. With the capacity to meet high-specification requirements and deliver high-performance solutions, they have emerged as titans in the global manufacturing arena. With further advancements in overmolding technology, these players will undoubtedly be at the forefront, pushing business innovation and generating huge value to customers around the world.