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Overmolding Services
Integrated Parts. Smarter Performance.
Overmolding bonds two or more materials into a single component — embedding grip, sealing, damping, and aesthetic features directly into the part. Fewer components, fewer assembly steps, and better performance built in from the start
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2+
materials in one part
Fewer
assembly steps
In-house
Finishing & assembly

Core Capabilties

One part. Multiple materials.
Better outcomes.

Overmolding replaces multi-component assemblies with a single integrated part — consolidating materials, functions, and manufacturing steps. PSI's overmolding programs are built on three outcomes: reduced part count, improved functional performance, and manufacturing consistency you can depend on at volume.

Reduce Part Count & Streamline Assembly
Multi-component consolidation
Where design allows, multiple components are consolidated into a single overmolded part — removing secondary assembly operations and the handling, inspection, and inventory that comes with them.
Fewer assembly steps
Cutting assembly steps lowers labor cost and reduces the potential for human error during production. Parts arrive ready to go into the next stage of your manufacturing process.
Supplier consolidation
With in-house assembly and supply chain capabilities alongside overmolding, PSI can manage subcomponent integration that would otherwise require separate vendors — reducing handoffs and simplifying your supply base.
Improve Functional Integration
Grip, seal, and damping features built in
TPE and TPU overmolds add soft-touch grip surfaces, sealing lips, and vibration-damping features that would otherwise require separate gaskets, grips, or pads bonded or assembled after molding.
Multi-material performance combinations
Rigid structural substrates combined with flexible overmold materials deliver performance combinations — impact absorption, chemical resistance, electrical insulation — that neither material achieves alone.
Complex geometries and mechanical interlocks
Undercuts, interlocking features, and complex interfaces between substrate and overmold are designed into the part from the start — creating bonds that are mechanical as well as chemical.
Increase Repeatability & Manufacturing Confidence
Interface geometry and process alignment
The interface between substrate and overmold is reviewed during DFM — ensuring mechanical interlock features, gate locations, and parting strategy are aligned before the tool is built.
Material selection and compatibility
Substrate and overmold material pairs are selected for chemical compatibility and bond strength — not just for individual performance properties. PSI validates compatibility before committing to tooling.
Consistent quality at production volume
Substrate handling protocols, process parameters, and in-process controls are locked during development and maintained throughout production — delivering the same quality on run 10,000 as on run one.
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Not sure which process is right?

Is overmolding right for your program?
Overmolding is the right choice when your design requires multiple materials in a single part, when soft-touch or sealing features need to be integrated rather than assembled, or when you're looking to reduce part count and assembly steps.

If you're not sure whether your application is a fit — or whether insert molding, two-shot molding, or standard assembly would serve better — talk to our team. We'll tell you quickly which approach makes the most sense.
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The PSI Difference

Partnership From Day One

From the first design conversation to final assembly, our team works alongside your team at every stage. Engineering, molding, decoration, and assembly all happen under one roof, with a single team accountable for quality, timing, and consistency from start to finish.

No handoffs to outside vendors. No gaps in communication. Just experienced people who know your part, understand your standards, and are invested in getting it right.

Less guesswork.

No surprises.

Better Outcomes.

PSI asks questions before  a tool is cut — what does this part need to do, where does it live, what can’t it fail at? Our engineers work alongside yours from day one, so the people building your parts are in lock step with the people who designed them. Good engineering shouldn’t feel complicated. It should just feel like it works.

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Mold Transfer capabilities

Already have tooling? Transferring to PSI is easier than you think.

PSI has a proven process for qualifying and transitioning molds from other suppliers — minimizing disruption to your program while improving the quality, service, and cost structure of your molded parts. Whether you’re reshoring, consolidating suppliers, or simply looking for a better partner, we make the move straightforward.

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