Overmoulding
At Nordell, we provide precision overmoulding services that enhance product performance, durability and design.
Overmoulding allows multiple materials to be combined into a single, integrated component.
Whether you are improving grip, adding sealing features, increasing impact resistance or refining aesthetics, our injection moulding team delivers reliable, production-ready solutions.
From concept support through to full-scale manufacture, we work with you to develop parts that meet demanding functional and commercial requirements.
Contact us to discuss your overmoulding project.
Why Choose Overmoulding?
- Integrated PerformanceCombine rigid and flexible materials to enhance grip, protection and durability within a single engineered component.
- Efficient Two-Stage ProcessA controlled two-stage moulding approach reduces secondary assembly while maintaining repeatability.
- Design FlexibilityIncorporate seals, soft-touch surfaces and contrasting materials to improve both function and aesthetics.
What Is Overmoulding?
Overmoulding is a manufacturing process in which one material, typically a thermoplastic or elastomer, is moulded over another substrate to form a single, integrated part.
This process allows different materials to be combined within one component, providing benefits such as improved grip, durability, comfort, and functionality. The result is a component that benefits from the strengths of each material while reducing assembly steps, eliminating the need for additional fasteners or adhesives in suitable applications, and improving overall integrity.
Overmoulding is widely used across industries where components require a combination of rigid structural support and softer, more flexible surfaces. Common applications include ergonomic handles, protective housings, seals, and grips, enabling manufacturers to achieve more complex designs while maintaining consistent quality and production efficiency.
This enables the combination of materials with different properties, for example:
- A rigid structural core with a soft-touch outer layer
- A rigid external housing and clear overmoulded window
- A decorative outer finish over a durable internal structure
Overmoulding Material Combinations
Plastic to Plastic Overmoulding
Combining rigid and flexible thermoplastics allows enhanced grip, sealing and impact resistance. Material compatibility is carefully assessed to ensure reliable bonding and long-term performance.
Plastic to Metal Overmoulding
Metal inserts or structural components can be overmoulded to create reinforced parts with integrated strength and protection. This is commonly used in tools, housings and structural assemblies.
Insert Overmoulding
Pre-formed components such as threaded inserts, pins or structural elements are placed within the mould and encapsulated during the overmoulding stage, reducing assembly steps.
Rubber to Plastic Overmoulding
Elastomer materials such as TPE or TPU can be moulded over rigid substrates to provide soft-touch surfaces, vibration damping and environmental sealing.
Industries we support
Nordell partners with OEMs, innovators, and production teams across diverse sectors, helping each achieve faster development, tighter tolerances, and long-term reliability.
- Medical & Healthcare
Cleanroom-produced consumables and precision assemblies - Electronics & Electrical
Housings, connectors, and encapsulated cable systems - Industrial & Engineering
High-strength, high-tolerance components - Environmental & Green Tech
Moulded parts for filtration and sustainability systems - Marine & Oil & Gas
Corrosion-resistant plastics for offshore conditions - Consumer Products
Reliable, repeatable manufacturing for OEM and retail goods
Electronics and Cable Solutions
For projects involving PCBs, connectors, cable assemblies or sensitive electronic components, please visit our dedicated Electronics Encapsulation page.
Overmoulding vs Two Shot Moulding
Overmoulding is typically completed as a two-stage process, where a substrate is moulded first and then transferred into a second moulding operation to apply the overmould.
For applications that require both materials to be injected within a single machine cycle, two-shot moulding may be more suitable.
Two-shot moulding uses specialised tooling and machinery to inject two materials sequentially within one automated process.
You can learn more about our Two-Shot Moulding services.
