Precision Insert and Over Molding Solutions

Insert and Over Molding Backed by In-House Metal Stamping Operations

DIAL is one of the few U.S. manufacturers that performs both metal stamping and insert or over molding entirely in-house. This integration gives you a single partner for producing hybrid components that bond plastic to metal with strength, precision, and repeatability.

Our in-house process eliminates the risks of outsourcing, shortens lead times, and ensures consistent quality. Whether you need structural support, sealing, ergonomic function, or cosmetic appearance, we help you build smarter, faster, and more reliably.

What is Insert Molding?

Insert molding is a process where pre-formed components (typically metal or threaded inserts) are placed into a mold, and plastic is injected around them. This creates a single molded part with improved strength, material bonding, and dimensional accuracy.

What is Over Molding?

Over molding is a process that applies a second plastic material over a molded part to improve grip, insulation, or aesthetics. This creates a unified part that combines materials with different hardness, textures, or colors.

Key Features of Insert and Over Molding

Build stronger hybrid components with greater control, fewer handoffs, and a faster path to production.

In-House Metal Stamping and Insert Molding

DIAL produces both the metal inserts and the molded plastic components, ensuring material compatibility, dimensional control, and reliable handoff between processes.

Precision Insert Placement and Over Mold Alignment

Custom tooling and process control deliver tight fit, proper bonding, and clean transitions between materials for structural or cosmetic parts.

Stronger, More Durable Parts

Our hybrid molding process creates fully bonded components that eliminate the need for fasteners, adhesives, or secondary operations.

Fewer Vendors and Faster Launches

With everything in one place, your programs move forward faster, with fewer risks, delays, or miscommunications between suppliers.

Insert Molding and Over Molding Product Examples

Insert Molded Coil Housing

Injection molded resin with terminal pin

Insert Molded Connector

Brass and ployamide part with insert molding

Insert Molded Terminal

Injection molded resin with terminal pins

Over Molded Plastic Shroud

Over-molded screen with glass filled nylon

Stamped Lead Frame With Insert Molding

Brass with nickel/gold plating and insert molding

Injection Molded Bracket

Injection molded bracket with metal stamped eyelets and compression limiters

Insert and Over Molding Applications

Automotive and Transportation

Shift knob assemblies with over molded grips
Terminal housings with embedded metal inserts
Molded brackets with integrated fasteners

Industrial and Commercial Equipment

Handles and housings with over molded grip layers
Reinforced components with stamped metal cores
Mounting plates with molded-in studs or threaded inserts

Electronics and Smart Devices

Multi-material button panels and interface housings
Over molded strain reliefs for cables and wires
Lightweight plastic enclosures with molded-in shielding

Consumer and Appliance Products

Two-color knobs and control panels
Functional grips on personal devices or handheld tools
Embedded inserts for screw mounts, hinges, or covers

Performance Benefits of Insert and Over Molding

Stronger, Smarter Assemblies

Replace multi-part assemblies with fully bonded hybrid components that improve mechanical strength and reliability.

Reduced Assembly and Labor Costs

Eliminate fasteners, adhesives, and secondary operations by combining materials into one efficient molded part.

Enhanced Product Lifespan

Protect against moisture, wear, and vibration with embedded inserts and sealed material transitions.

Fewer Vendors, Faster Results

With metal inserts molded in-house, DIAL simplifies your supply chain and accelerates launch timelines.

Insert and Over Molding Capabilities

A fully integrated process designed for tight-tolerance hybrid parts with enhanced durability, speed, and design flexibility.

Supported Insert Types

Stamped metal components made in-house
Brass, copper, stainless steel, aluminum inserts
Threaded, knurled, or custom-cut metal features

Compatible Resins

ABS, Nylon, PP, PC, TPU, TPE
Soft-touch and rigid combinations
Glass-filled and high-performance blends

Tooling & Mold Options

Rotary platen, and standard over molding tools
Tight-tolerance insert registration
Automated or manual insert loading

Common Applications

Terminal housings, knobs, strain reliefs, buttons
Grip-enhanced handles, multi-material enclosures
Plastic parts with molded-in fasteners or guides

Need help choosing the right material?

Let DIAL Handle Your Most Demanding Multi-Material Projects

When you need plastic and metal to work together seamlessly, DIAL brings the engineering precision and production capacity to get it done right. From connector housings to high-touch handles, we mold with purpose — and performance.