Injection Molding for Medical Devices: Overmolding for Superior Functionality and Comfort

When patient health is on the line, advanced medical device manufacturing techniques can raise the bar on comfort, safety, and functionality. That’s why injection molding for medical devices, especially overmolding, is an increasingly popular solution with many manufacturers.

From surgical instruments to diagnostic equipment, overmolding helps medical device designers improve ergonomics, durability, and the user experience. Let’s take a closer look at this standout manufacturing technology and how the expert engineering team at In’Tech can partner with you to improve the functionality and comfort of your medical devices.

Benefits of Overmolding Injection Molding for Medical Devices

Overmolding is an injection molding process. It molds a soft, flexible material, such as thermoplastic elastomer (TPE), over a rigid base, such as steel, polycarbonate, or ABS. This allows medical device designers to incorporate multiple materials and textures into a device without fasteners or adhesives. Overmolding offers medical device manufacturers several benefits over other fabrication techniques.

Improved Comfort and Ergonomics

Soft-touch grips or textured surfaces on clinical instruments can reduce fatigue and increase control, especially during long procedures. An ergonomic grip on a tool or diagnostic device can be the difference between precision and strain.

Enhanced Functionality

Overmolding allows you to seal enhanced functionality directly into your device, including non-slip surfaces and color-coded features. Because they are a part of the device and not attached with adhesive or a fastener, these features won’t compromise the performance or durability of the device.

Durable and Chemical Resistant

Speaking of durability, overmolding offers superior performance in rigorous, repeated sterilization processes. Overmolded parts can withstand autoclaving, UV, and chemical disinfection without degrading. They will maintain their flexibility and seal to the substrate throughout their lifecycle.  

Efficient Design

Overmolding is an efficient process that can cut down on manufacturing time and costs. Because it combines materials into one seamless part, it reduces the number of components and assembly steps in your manufacturing  process. This leads to lower labor costs, fewer potential points of failure during fabrication, and a sleeker, more compact design.

Real-World Examples of Overmolding for Medical Devices

Let’s take a look at two examples of how overmolded medical equipment performs in the field. A manufacturer of surgical devices wants to develop a line of ergonomic scalpels. They use overmolding to combine stainless steel blades with ergonomic TPE grips. The TPE is overmolded directly onto the metal to create a soft-touch, non-slip grip. This reduces hand fatigue and ensures better control during surgical procedures.

Overmolding can improve the performance of seals and gaskets. Rather than incorporating a separate rubber seal that can detach from the plastic housing of a piece of medical equipment, overmolding can combine the rigid frame with a flexible seal in one, single piece. This removes the risk of the seal detaching during use or sterilization.

Work with In’Tech Industries for Your Overmolding Needs

If you are ready to improve the performance, functionality, and safety of your medical products, get in touch with the expert team at In’Tech Industries. We work with medical device designers from concept through production to ensure each part meets your demanding standards for precision and performance.

Our knowledgeable team has deep experience in material selection, mold design, and regulatory compliance to ensure we recommend the optimal rigid and flexible materials for your device and ensure high-quality products with minimal rework.

Whether you’re developing surgical tools, wearable devices, or diagnostic kits, In’Tech’s overmolding capabilities may be the right fit for your needs. Contact us today to speak with our expert team about your project.