Google Icon

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.

Service Process

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.

"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

"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

"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

"Great expertise and people!"

Rick Chen
Rick Chen

"driven with details ... Very impressive"

Lawrence Dathe
Lawrence Dathe

"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

"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

"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

"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

"Great expertise and people!"

Rick Chen
Rick Chen

"driven with details ... Very impressive"

Lawrence Dathe
Lawrence Dathe

"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

"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

"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

"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

"Great expertise and people!"

Rick Chen
Rick Chen

"driven with details ... Very impressive"

Lawrence Dathe
Lawrence Dathe

"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
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 of Evok Polymers

Paul Dathe

Founder

Paul Dathe founded Evōk Polymers with a singular mission: delivering the highest quality injection molded components at optimized pricing through proprietary technology and white-glove service. With over 25 years specializing in custom plastic component manufacturing, Paul's expertise spans engineering, product design, and complex problem-solving in injection molding. His career highlights include leading new product development at Caliber Products, where he launched 13 products while growing sales 540% and achieving 100% client retention. Paul's technical depth encompasses tooling design, functional assessments, 3D modeling, prototype fabrication, tolerance analysis, and mold flow studies. Previously, as Senior Mechanical Engineer at Entegris, he managed a $40 million product line of ultra-clean liquid delivery systems for semiconductor applications. Paul holds four U.S. utility patents, is a Six Sigma black belt, and earned his Bachelor of Science in Mechanical Design from Bemidji State University. He is an active member of Allied Executives Business Leadership Peer group and the Institute of Packaging Professionals.

Jason Weber

Industrial Designer

Jason is a seasoned industrial designer with a passion for creating innovative and functional products. His design philosophy is deeply influenced by his life within a multi-generational household, where living with his wife, two sons, and mother nurtures an innate empathy that shapes his approach to product development. This unique perspective allows Jason to keenly observe human behavior and translate those insights into designs that truly resonate with end users. His ability to understand how people interact with products brings invaluable user-centered thinking to overmolding projects, ensuring ergonomic features and tactile elements are optimized for real-world use. In his leisure time, Jason enjoys indulging in his passions for cooking, gaming, and unwinding, which fuel his creative problem-solving abilities.

Shawn Monitor, Sr. Industrial Designer at Evok Polymers

Shawn Monitor

Sr. Industrial Designer

Shawn is an ever-curious creative force who has contributed to some of the most advanced manufacturing projects over the past two decades. His particular expertise lies in graphically and physically communicating evolving design concepts and complex part features through sophisticated mechanical and visual prototypes crafted in diverse materials. Shawn's proficiency extends to creating photorealistic renderings using Otoy OctaneRender® and developing detailed layouts, diagrams, and branding elements with Adobe Creative Cloud. His role in finding mechanical molded part solutions that can be prototyped and validated before tooling has proven instrumental in de-risking large-scale overmolding projects. Shawn's involvement in pre-molding design reviews has significantly reduced manufacturing challenges and improved first-article success rates. He holds several patents and has conducted research spanning consumer products to biotech and medical applications. Outside work, Shawn practices photography and frequently enjoys the vibrant Twin Cities live music scene.

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

Daniel D. Hoyt, Ph.D.

Business Development Manager

Daniel's expertise in system and process design, coupled with his ability to cultivate strategic partnerships, distinguishes him as a leader in manufacturing innovation. His passion for collaboration and continuous improvement drives his work creating Lean Partnership-Based Organizations that empower businesses of all sizes. At Evok, Daniel leads transformative initiatives that challenge traditional paradigms in part design, prototyping, tooling, and injection mold manufacturing. His vision extends beyond simple disruption—he's building a community centered on mutual benefit, genuine partnership, and sustainable growth. Daniel's commitment to establishing new industry benchmarks for collaborative success aligns perfectly with Evok's mission to revolutionize overmolding and custom injection molding. His proficiency as a facilitator, public speaker, teacher, and coach, combined with exceptional team-building and mentorship skills, makes him an invaluable asset to both the Evok team and the clients we serve.

Natalie Weber, Operations Officer at Evok Polymers

Natalie Weber

Operations Officer – LIV

Natalie, a dedicated apprentice in product design and management, embodies the harmonious blend of creativity and environmental responsibility. Her innate curiosity and discerning eye for innovation drive her to explore the convergence of design excellence with ecological consciousness. Immersed in design principles since childhood, Natalie deeply understands the profound impact manufacturing processes and material choices can have on our planet. This early awareness, combined with her education in sustainability, propels her commitment to infusing eco-conscious thinking into every facet of product development. Under the mentorship of her father and seasoned industry professionals, Natalie delves into the intricacies of overmolding and injection molding, eagerly absorbing knowledge about diverse materials, manufacturing techniques, and emerging technologies—always considering their environmental footprint. Her journey extends beyond creating functional components; Natalie aspires to shape a future where precision manufacturing seamlessly integrates with sustainability, leaving a positive legacy for generations.

Julie Young, Accounting and Finance Manager at Evok Polymers

Julie Young

Accounting and Finance Manager

Julie has been an integral part of Evok since its inception, bringing meticulous attention to detail and thorough understanding of financial principles to efficiently manage and maintain accurate financial records. As an experienced bookkeeper, 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, supporting regulatory compliance and fiscal health. Her commitment to professionalism and confidentiality provides the foundation for reliable financial operations that support both the Evok team and our valued customers. Julie ensures all vendors receive timely payment, maintaining the strong supplier relationships that are critical to our overmolding manufacturing excellence.

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 You can also send us a quick email at