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Custom Overmolding Services | Rubber-Over-Plastic Manufacturing

Transform your product designs with Evok's precision overmolding services—combining rigid plastics with soft-touch elastomers for enhanced ergonomics, durability, and functionality. Our 25 years of injection molding expertise ensures flawless rubber-over-plastic integration, from prototype to production, delivering components that meet exact specifications while optimizing manufacturability and cost-effectiveness for your market success.

Precision overmolded plastic component showing rubber grip over rigid plastic substrate

Our Custom Overmolding Services

Complete overmolding solutions from design optimization to high-volume production, ensuring perfect material bonding and dimensional accuracy.

Two-Shot Overmolding

Advanced two-shot injection molding that combines rigid and elastomeric materials in a single molding cycle, eliminating assembly steps while ensuring superior bond strength and dimensional precision for complex multi-material components.

Insert Overmolding

Precision overmolding over pre-placed inserts including metal components, electronics, or rigid plastic substrates. Our process ensures perfect encapsulation, mechanical retention, and protection while maintaining tight tolerances around critical features.

Material Selection & Testing

Expert guidance on compatible material pairings for optimal chemical bonding, analyzing substrate-overmold compatibility, durometer requirements, and performance criteria. We validate selections through application testing to ensure long-term durability.

Overmold Design Optimization

Comprehensive design-for-manufacturing review focused on overmolding success factors including draft angles, undercut management, gate placement, material flow analysis, and bonding surface preparation to maximize bond strength and minimize defects.

Prototype Overmolding

Rapid prototype overmolded parts for design validation and functional testing. We utilize various prototyping methods to verify material compatibility, bond strength, and part performance before committing to production tooling investment.

Production Overmolding

High-volume overmolding production with rigorous process controls, automated quality inspection, and continuous monitoring. Our optimized tooling and process parameters ensure consistent bond quality, dimensional accuracy, and cost-effective manufacturing at scale.

Overmolding manufacturing process showing injection molding machine and tooling

Our Proven 5-Step Overmolding Process

Design Analysis & Material Compatibility Review

We begin by thoroughly analyzing your part design, evaluating substrate material, overmold material selection, and bonding requirements. Our engineers assess draft angles, wall thicknesses, undercut geometry, and gate locations while considering chemical compatibility and mechanical bonding characteristics to ensure manufacturability and optimal performance.

Prototype Development & Bond Validation

Precision Tooling Engineering

Process Qualification & First Article Approval

Production Launch & Continuous Quality Monitoring

Proven Performance

Trusted by Industry Leaders

Join brands like Polaris, Rollerblade, and Boston Scientific who trust Evok for mission-critical overmolded components.

"driven with details ... Very impressive"

Lawrence Dathe
Lawrence Dathe

"Great expertise and people!"

Rick Chen
Rick Chen

"Evok provided exceptional service! Paul and the studio team demonstrated amazing expertise and professionalism throughout the process. They exceeded expectations with precision and timely execution. Highly recommend for any project requiring top-notch design solutions."

Jason Salveson
Jason Salveson

"Great customer service! Paul is super dedicated."

Mo Amin
Mo Amin

"Paul is very knowledgeable and passionate regarding all facets of plastics manufacturing."

Matt Maskell
Matt Maskell

"Amazing business and amazing person to work with.Paul and I grew up together he has always had attention to detail in everything he has ever done,my company has used him a couple times now and are so pleased with the outcome I would recommend the company to anyone, once again..."

Kevin Nattress
Kevin Nattress

"Had a Great to work with Paul and it has been great! Has a plethora of knowledge and was great to learn from."

Landen Pool
Landen Pool

"driven with details ... Very impressive"

Lawrence Dathe
Lawrence Dathe

"Great expertise and people!"

Rick Chen
Rick Chen

"Evok provided exceptional service! Paul and the studio team demonstrated amazing expertise and professionalism throughout the process. They exceeded expectations with precision and timely execution. Highly recommend for any project requiring top-notch design solutions."

Jason Salveson
Jason Salveson

"Great customer service! Paul is super dedicated."

Mo Amin
Mo Amin

"Paul is very knowledgeable and passionate regarding all facets of plastics manufacturing."

Matt Maskell
Matt Maskell

"Amazing business and amazing person to work with.Paul and I grew up together he has always had attention to detail in everything he has ever done,my company has used him a couple times now and are so pleased with the outcome I would recommend the company to anyone, once again..."

Kevin Nattress
Kevin Nattress

"Had a Great to work with Paul and it has been great! Has a plethora of knowledge and was great to learn from."

Landen Pool
Landen Pool

"driven with details ... Very impressive"

Lawrence Dathe
Lawrence Dathe

"Great expertise and people!"

Rick Chen
Rick Chen

"Evok provided exceptional service! Paul and the studio team demonstrated amazing expertise and professionalism throughout the process. They exceeded expectations with precision and timely execution. Highly recommend for any project requiring top-notch design solutions."

Jason Salveson
Jason Salveson

"Great customer service! Paul is super dedicated."

Mo Amin
Mo Amin

"Paul is very knowledgeable and passionate regarding all facets of plastics manufacturing."

Matt Maskell
Matt Maskell

"Amazing business and amazing person to work with.Paul and I grew up together he has always had attention to detail in everything he has ever done,my company has used him a couple times now and are so pleased with the outcome I would recommend the company to anyone, once again..."

Kevin Nattress
Kevin Nattress

"Had a Great to work with Paul and it has been great! Has a plethora of knowledge and was great to learn from."

Landen Pool
Landen Pool
The Evok Advantage

Why Choose Evok for Overmolding?

25 years of injection molding mastery focused on multi-material component excellence.

Overmolding Expertise

Our specialized team brings deep knowledge of material science, bonding chemistry, and process optimization to ensure flawless rubber-over-plastic integration every time.

Design-First Approach

We proactively identify and resolve overmolding design challenges early, optimizing for manufacturability, bond integrity, and cost efficiency before tooling begins.

Complete Transparency

Upfront cost breakdowns, detailed process documentation, and open communication throughout development ensure you understand every aspect of your overmolding project investment.

Quality Assurance

Rigorous qualification protocols with comprehensive dimensional inspection, bond strength testing, and Six Sigma process controls guarantee consistent, defect-free overmolded components.

Meet Our Overmolding Experts

Passionate professionals dedicated to your manufacturing success.

Paul Dathe, Founder and Chief Engineer at EVOK Polymers

Paul Dathe

Founder

Paul Dathe founded Evōk Polymers with a singular mission: delivering the highest quality injection molded components at the lowest possible price through proprietary technology and deep industry expertise. With over 25 years specializing in engineering, product design, and solving complex injection molding challenges, Paul brings unparalleled depth to every project. He holds four U.S. utility patents and earned Six Sigma black belt certification, applying rigorous process optimization to mold design engineering. Prior to founding EVOK, Paul led new product development at Caliber Products, launching 13 products while growing sales 540% and expanding from 25 to 144 customers with 100% retention. His responsibilities spanned tooling design, functional assessments, 3D modeling, prototype fabrication, tolerance analysis, and mold flow studies. Earlier, as Senior Mechanical Engineer at Entegris, Paul managed a $40 million product line of ultra-clean liquid delivery systems for semiconductor applications. He began his career at Rollerblade in design and prototyping before serving in senior engineering roles at General Mills and Boston Scientific. Paul earned his Bachelor of Science in Mechanical Design from Bemidji State University with emphasis in rapid prototyping and 3D computer modeling. He's an active member of Allied Executives Business Leadership Peer group and the Institute of Packaging Professionals.

Jason Weber, Industrial Designer at EVOK Polymers

Jason Weber

Industrial Designer

Jason is a seasoned industrial designer with a passion for creating innovative and functional injection molded products. His design philosophy is deeply influenced by his life within a multi-generational household with his wife, two sons, and mother, which nurtures innate empathy and keen observation of human behavior—qualities that translate directly into user-centered design excellence. Jason brings creative vision to EVOK's engineering projects, balancing aesthetic refinement with manufacturing practicality. His ability to understand how people interact with products ensures that every component he designs not only meets technical specifications but also delivers intuitive functionality and ergonomic comfort. Jason's multidisciplinary approach bridges the gap between pure engineering and real-world application, helping clients create products that resonate with end users. Outside the studio, Jason finds inspiration through cooking, gaming, and relaxation, activities that fuel his creative process and problem-solving abilities.

Shawn Monitor, Sr. Industrial Designer at EVOK Polymers

Shawn Monitor

Sr. Industrial Designer

Shawn Monitor has been an instrumental creative force on some of the most advanced injection molded seating and component projects of the last two decades. His particular expertise lies in graphically and physically communicating evolving design concepts and intricate part features through complex mechanical and visual prototypes built in diverse materials. Shawn creates photorealistic renderings using Otoy OctaneRender® and develops professional layouts, diagrams, and logos with Adobe Creative Cloud, providing clients with clear visualization of engineering concepts before tooling commitment. His deep involvement in pre-molding design reviews has significantly reduced risk on numerous large-scale projects by identifying and resolving potential manufacturing issues early in the development cycle. Shawn excels at finding mechanical molded part solutions that can be prototyped and validated prior to expensive production tooling, saving clients time and money while ensuring design intent is maintained. He holds several patents reflecting his innovative approach to injection mold component design. Beyond his professional achievements, Shawn practices photography and enjoys the vibrant Twin Cities live music scene, interests that sharpen his visual communication skills and creative thinking.

Daniel D. Hoyt, Ph.D., Business Development Manager at EVOK Polymers

Daniel D. Hoyt, Ph.D.

Business Development Manager

Daniel brings exceptional expertise in system and process design engineering, coupled with strategic partnership cultivation that sets EVOK apart in the injection molding industry. His passion for innovation and collaboration drives initiatives that challenge traditional norms in part design, prototyping, tooling, and injection mold manufacturing. Daniel's vision extends beyond disruption—he's building a community centered on continuous improvement, mutual benefit, and genuine partnership that empowers small and mid-sized businesses to compete at the highest levels. His leadership focuses on creating Lean Partnership-Based Organizations that optimize engineering processes and deliver sustainable growth. Daniel's proficiency as a facilitator, public speaker, teacher, and coach, combined with exceptional team-building and mentorship abilities, accelerates EVOK's mission to transform industry standards. Under his guidance, EVOK establishes new benchmarks for collaborative engineering success, ensuring clients receive not just technical expertise but strategic insights that drive their competitive advantage in demanding markets.

Natalie Weber, Operations Officer at Evok Polymers

Natalie Weber

Operations Officer – LIV

Natalie is a dedicated apprentice in product design and management who embodies the harmonious blend of creativity and sustainability in injection mold engineering. Possessing innate curiosity and a discerning eye for innovation, she tirelessly explores where design converges with environmental consciousness—bringing fresh perspectives to material selection and dematerialization strategies. Immersed in intangible design principles since childhood, Natalie grasps the profound impact injection molded products can have on the planet, driving her commitment to infusing eco-consciousness into every project facet. Her education in sustainability, combined with hands-on mentorship from seasoned professionals, accelerates her mastery of product design intricacies. Natalie investigates diverse materials, manufacturing techniques, and emerging technologies, always evaluating their ecological footprint and lifecycle implications. Her journey extends beyond creating aesthetically pleasing components—she's shaping a future where injection mold design engineering seamlessly integrates sustainability principles, leaving a positive legacy for generations while meeting demanding performance specifications.

Julie Young, Accounting and Finance Manager at Evok Polymers

Julie Young

Accounting and Finance Manager

Julie Young has been an integral part of Evok since its inception, bringing meticulous attention to detail and thorough financial expertise to the organization. As an experienced accounting professional, she excels in organizing and categorizing transactions, reconciling accounts, and producing clear, concise financial reports that enable informed business decisions. Julie's proficiency in accounting software ensures streamlined processes and timely delivery of financial information, maintaining compliance with all regulatory requirements. Her dedication to professionalism and confidentiality provides the financial backbone that supports Evok's operations and growth. Beyond standard bookkeeping, Julie plays a critical role in vendor relationship management, ensuring all partners are paid promptly and maintaining the trust-based environment that is central to Evok's values. Her reliable financial services support both the team's effectiveness and customer satisfaction by ensuring resources are properly allocated to deliver exceptional injection molding solutions.

Frequently Asked Questions

What is the process of overmolding plastic?

Overmolding is a two-stage injection molding process where a rigid plastic substrate is first molded, then a second material (typically a thermoplastic elastomer or rubber) is molded over or around it. The substrate can be placed manually or robotically into a second mold cavity, where the overmold material is injected. The materials bond through mechanical interlocking and/or chemical adhesion. Key success factors include proper material compatibility, substrate surface preparation, controlled temperatures, and optimized gate placement to ensure complete coverage and strong bonding without defects.

What are the rules for overmolding design?

What is silicone over molding?

What materials can be overmolded together?

How much does overmolding cost compared to assembly?

Can you overmold over metal inserts or electronic components?

What is the typical lead time for overmolded parts?

How do you ensure consistent bond strength in overmolding?

Have More Questions About Overmolding?

Our injection molding experts are ready to discuss your specific application and design requirements.

Certified Excellence

Awards and Recognition

Six Sigma Black Belt certification logo

Six Sigma Black Belt

Process excellence and quality assurance certification

Institute of Packaging Professionals member logo

Institute of Packaging Professionals

Member of leading packaging industry organization

25 years of manufacturing excellence badge

25+ Years Manufacturing Excellence

Proven expertise serving industry leaders

Ready to Transform Your Product Design with Overmolding?

Share your project details and our overmolding specialists will provide expert guidance, design recommendations, and a detailed quote tailored to your requirements.

Contact Us Today

For immediate assistance, feel free to give us a direct call at +1 612-991-2001.