What is the Difference between Double Shot Molding and Overmolding?
Among various types of injection molding methods, double shot molding and overmolding are perhaps the most popular injection molding methods manufacturers use in their manufacturing production. Double shot molding and overmolding have similar processes that combine two different materials of different colors to create a single product or part using multiple injection molding shots. However, there are some different aspects that make them differ from each other.
In this guide, you will learn about the differences between double shot molding and overmolding, along with considerations you should take before choosing between the two options.
Understanding More about Double Shot Molding in Manufacturing
Double shot molding is a type of injection molding process whereby you apply two injection molding shots that will allow different materials of different colors to combine into a single injection molded-product. In double shot molding, you often need to use different molds that will get connected into the primary mold, allowing the materials you injected to bond with each other to form a single product. Double shot injection molding is a complex injection molding process that will require multiple steps for you to complete, and it is suitable for large production volumes.
Understanding More about Overmolding in Manufacturing
Overmolding is the two-shot or multiple shot process whereby you apply two different injection molding shots into the primary mold. However, with overmolding, you will apply the second injection molding shot over/on top of the primary shot. You will need to wait for the primary injection molding shot to cool down first, and then you will need to apply the second injection molding shot over it. Overmolding often uses a single primary mold with different layers. The first layer is for the primary shot, while the second layer is for the secondary or overmold shot. This injection molding method is much simpler than the double shot molding, and it is more suitable for low production volumes.
Key Differences between Double Shot Molding and Overmolding
Double shot molding and overmolding might look like similar injection molding methods, but there are some aspects that differentiate between them. Here are some key differences between double shot molding and overmolding:
– The way the process combines different materials. With double shot molding, you will combine the materials in different mold parts, such as when you combine the left side and the right side of the injection-molded product. Meanwhile, with overmolding, you are combining the second material over the primary material, so you can perform this process in a single mold.
– High vs. low production. Double shot molding is much more suitable for the high-volume production run, whereas overmolding is suitable for the low-volume production run. So, depending on the volume of your production, you can choose between double shot molding and overmolding.
– Separate molds vs. the same primary mold. Double shot molding often uses separate molds to combine the different materials and colors, which can also help you create a larger product size. Overmolding, on the other hand, often uses the same primary mold with different mold layers, with the first layer used for the primary substrate and the second layer used for the overmold substrate.
– Complexity of the process. When you take a look at both double shot molding and overmolding, these processes are generally more complex than the regular plastic molding process. However, compared with each other, the double shot molding will involve a more complex injection molding process than overmolding.
– More complex vs. simpler design. Double shot molding allows you to create flexible designs with complex geometries for the molds. Meanwhile, compared to the double shot molding, overmolding uses simpler designs with more limitations and restrictions in its geometry.
Considerations before Choosing between Double Shot Molding and Overmolding
You will need to take some considerations before deciding on whether you need to use double shot molding or overmolding, such as considering your budget, product size, and so on. Here are some considerations you need to keep in mind before choosing between double shot molding and overmolding:
– The size of your product. Double shot molding can handle bigger product sizes with multiple components in it, whereas overmolding can handle smaller products with fewer components in it. So, depending on your product size, you can pick between double shot molding and overmolding.
– Budget. Double shot molding will often require you to create the primary mold with at least two mold parts, meaning that you will need to prepare a bigger budget for the tooling process. Meanwhile, overmolding will require you to create only the primary mold, which means less tooling costs for you. So, your budget is another consideration to choose between double shot molding and overmolding.
– Production volumes. Double shot molding is more suitable for large production volumes, because the bigger tooling and other costs involved in this process can only bring you the best profit potential when you produce your products in large quantities. Meanwhile, with cheaper tooling and injection molding cost, overmolding can still be profitable even when you use it in small-quantity production. So, pick the double shot molding process if you want to produce large-quantity products and choose overmolding if you want to produce small-quantity products.
– Design complexity. Double shot molding will allow you to apply more complex designs for your products, so choose this option if your products have complex design requirements. Meanwhile, for simpler designs, overmolding is the best production method you can use.
Conclusion
Double shot molding and overmolding share the similar injection molding process that allows you to combine different materials and colors into a single injection-molded product. However, each method has their own uniqueness that makes them differ from the other. Generally, double shot molding is the injection molding process that is much bigger than overmolding, which you can use for large production volumes. Meanwhile, overmolding is a more budget-friendly option you can use in small production volumes. TEAM Rapid provides various injection molding services, including overmolding and double shot molding, at the best price. Our company is based in Hong Kong and owns a factory in Zhongshan, China. You can request a quote for your project by contacting us through the website.
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