CDI offers precision overmolding services to enhance the performance, reliability, and visual appeal of cable assemblies, wire harnesses, and individual components. We work closely with our customers to deliver parts that perform in demanding environments-without compromising speed, cost-efficiency, or manufacturability.
Overmolding combines two or more materials into a single component. By molding a thermoplastic or elastomer layer over a rigid substrate, this process provides protection, insulation, and added functionality. It also helps streamline designs, reduce part count, and simplify assembly.
Whether you’re looking to protect sensitive electronics, improve cable durability, or create a more ergonomic interface, our overmolding services are designed to support both prototyping and full production runs.
About Overmolding
Overmolding is a versatile manufacturing method used to enhance the function, form, and longevity of components. The process creates a seamless bond between materials-typically a soft outer layer molded over a rigid base. This improves mechanical strength, prevents water and dust ingress, and helps shield against impact or vibration.
CDI supports multiple overmolding approaches, including two-shot injection and co-injection molding. We work with a range of thermoplastic materials to meet specific project needs for strength, flexibility, or chemical resistance.
The flexibility of overmolding makes it ideal for applications across defense, aerospace, industrial, commercial, and medical industries.
Types of Overmolding
CDI offers overmolding services for a variety of applications, with specialized capabilities in micro overmolding and cable overmolding.
Micro Overmolding
Micro overmolding is used to encapsulate small, delicate components such as sensors, wiring, and microcircuits. This precision process ensures reliable protection from environmental damage and mechanical stress without adding unnecessary bulk. It’s essential for applications where space and performance are equally critical.
Cable Overmolding
Cable overmolding increases the durability and flexibility of cables by adding a protective layer that reduces wear, provides strain relief, and enhances electrical insulation and safety.
Benefits of Overmolding
Overmolding delivers a wide range of benefits, including:
- Enhanced Durability. Overmolding joins materials with different properties-such as a rigid base and a flexible outer layer-to increase resistance to impact, abrasion, and environmental stress. This results in longer product life and fewer replacements.
- Improved Performance. High-performance materials used in overmolding can add strength, resist heat and chemicals, and form seals that protect sensitive components from moisture and debris.
- Enhanced Safety and Compliance. Overmolded parts can improve safety with features like non-slip surfaces and support compliance by using materials that meet industry regulations.
- Visual and Branding Appeal. Color and texture options allow for improved aesthetics and product differentiation, supporting both form and function.
- Cost Savings and Efficiency. Although setup costs can be higher, overmolding reduces secondary assembly, minimizes defects and material waste, and lowers warranty and replacement expenses over time.
Why CDI?
CDI builds quality into every stage of the overmolding process. Our tailored approach ensures each part is manufactured to meet its functional and environmental demands. We help clients navigate material selection, part design, and tooling with speed and flexibility, whether you’re developing a new product or optimizing an existing one.
With capabilities suited for both rapid prototyping and production-scale volumes, we support customers across a wide range of industries and use cases.
Ready to get started? Contact us to learn how our overmolding services can support your next project.