ESKY manufactures custom silicone overmolded components using plastic, metal and engineered inserts for applications that require sealing, grip, cushioning, protection or integrated soft-touch surfaces.
Product development and dedicated tooling around your application.
Quality control, assembly, packaging and shipment coordination.
WHAT WE OVERMOLD
Explore substrate combinations, insert molding and functional applications. Material compatibility and tooling requirements are reviewed during DFM.
Silicone overmolded onto plastic housings and structures for sealing, grip and protection.
Silicone bonded around metal inserts and hardware for mounting and durable assemblies.
Sealing beads, gasket surfaces and soft-touch areas integrated into the overmolded part.
ENGINEERING CONSIDERATIONS
Successful overmolding depends on more than material choice. Substrate compatibility, insert positioning, local shut-offs, gate location, silicone flow, bonding method and molding pressure all affect part quality.
Substrate compatibility depends on grade, surface condition and bonding method — reviewed at DFM.
Primer, self-bonding LSR or mechanical locking is selected based on substrate and application.
Gate and flow path design ensures silicone fills around the insert without air traps.
Shut-off geometry keeps silicone off critical contact or sealing surfaces.
Insert positioning and support prevent shift during injection.
Flash control around inserts and sealing surfaces is managed through shut-off design and pressure.
Demolding and part protection prevent damage during removal from the mold.
PROCESS
Early DFM review addresses material, bonding and tooling risks. Trial molding and validation confirm part performance before mass production.
Bond area, shut-offs, draft and substrate compatibility are reviewed before tooling.
Bond strength and shut-off quality are confirmed on samples, with the bonding route selected by substrate.
Process parameters are locked after approval to keep bond quality stable across batches.
CASE STUDIES
Improving mold shut-offs, insert positioning and process control to keep silicone off electrical contact areas.
Managing support, positioning, flow and molding pressure around flexible electronic circuits.
Managing magnet positioning and molding conditions to protect magnetic performance during overmolding.
FAQ
START A CUSTOM PROJECT
Share your drawing, reference sample or product idea. Tell us about the application, material requirements and estimated quantity so we can review the next steps.
PROJECT INTAKE
Send your CAD file, drawing or sample. We can review the substrate, silicone, tooling route and critical sealing areas before quotation.