Kinghe's professional Secondary Forming Injection Molding service (also known as two-material molding, overmolding, or two-step injection molding) involves two independent injection molding processes that firmly bond a first hard plastic substrate with a second soft plastic/colorant, giving the product structural strength, a comfortable feel, an attractive appearance, and multifunctional characteristics.
Compared to traditional single-color injection molding and post-assembly methods, secondary molding eliminates the need for glue, splicing, and additional assembly. It achieves advanced effects such as a hard plastic skeleton with a soft plastic overlay, two-color differentiation, anti-slip grip, waterproof sealing, and layered appearance, comprehensively improving the product's feel, appearance, durability, and safety.
We possess a mature process parameter library, stable molding conditions, and strict control over interface bonding, ensuring that the hard and soft materials do not detach, delaminate, or crack, maintaining high strength and high quality even after long-term use.
Based on product function and appearance requirements, we provide optimization of the base material and overlay structure, injection sequence planning, and bonding surface reinforcement to ensure a strong bond between the two layers, preventing detachment.
Supports hard plastic base layer + soft plastic overlay, achieving anti-slip, shock absorption, waterproofing, and a comfortable feel, widely used in handheld parts, grips, buttons, tabletop game accessories, and lamp housings.
Secondary Forming Injection Molding combines materials with different colors, transparency, and hardness through two injection molding processes, enhancing the visual appeal and brand recognition. Multi-color effects can be achieved without printing.
Rigorous testing and verification of bonding strength, adhesion, soft rubber hardness, and color difference ensure high consistency, stable yield, and reliable quality in mass production.
Covering the entire process from mold making, primary injection molding, secondary injection molding, appearance inspection, dimensional control, post-processing, and packaging and shipping, eliminating the need for multiple intermediaries for customers.
Through optimized interface structure and material matching, a strong bond is achieved, preventing delamination and separation even under long-term bending, compression, and aging.
Achieving Both Comfort and Strength. Hard rubber provides structural support and stability, while soft rubber enhances anti-slip properties, shock absorption, and grip comfort, making it particularly suitable for high-end toys, board games, lamps, and handheld products.
Two-tone/layered one-piece molding results in a clean, seamless, and glue-free appearance, offering a more premium look and brand image than single-color products.
Eliminating post-assembly, gluing, molding, and splicing processes improves production efficiency, reduces labor costs and assembly defects, resulting in a higher overall cost-performance ratio.
The soft rubber coating creates a sealed cushioning structure, enhancing product durability and environmental adaptability, making it suitable for export to high-end markets in Europe and America.
Kinghe Secondary Forming Injection Molding is widely used in high-end board game controllers and pieces, anti-slip shells for LED lights, grips for handheld toys, buttons for electronic products, anti-slip products for mothers and babies, tool shells, instrument buttons, household plastic accessories, outdoor plastic parts, waterproof sealing structural components, and other product fields with high requirements for comfort, appearance, and strength.
1. Client: A high-end European strategy board game brand
2. Client Needs: To develop a high-quality board game control accessory, requiring a soft, non-slip surface, comfortable feel, a strong bond between the soft and hard materials to prevent delamination, a two-tone design for differentiation, and resistance to peeling and cracking even after long-term, high-frequency use.
3. Service Process: Kinghe provides clients with a complete Secondary Forming Injection Molding solution. First, a hard plastic structural layer is injection molded, followed by a secondary overmolding using a specialized soft plastic material. This optimizes the bonding surface structure to improve adhesion, and strictly controls hardness, color difference, and bonding strength. The entire product line has passed EU RoHS and REACH environmental and safety tests.
4. Collaboration Achievements: The product boasts a comfortable feel, excellent anti-slip effect, and a premium two-tone appearance. It shows no delamination, cracking, or deformation even after long-term use. The client's initial order of 150,000 sets passed inspection on the first try, and subsequent repeat orders have solidified their position as a long-term, stable strategic client of Kinghe.
Q: What is the difference between two-stage molding and two-tone injection molding?
A: Two-stage molding involves two sequential injection molding steps, making it more suitable for soft rubber overlays, anti-slip grips, and waterproof sealing structures. Two-tone injection molding is simultaneous injection molding, more suitable for purely two-tone appearance parts. Both are suitable for different scenarios, and we can provide corresponding solutions for both.
Q: Is the bond between the soft and hard rubber in two-stage molding strong? Will it fall off?
A: The bonding strength is very reliable. Through structural optimization, material matching, and precise control of process parameters, we ensure a strong bond between the two layers. Bending, pulling, and aging tests show no signs of detachment or delamination.
Q: What material combinations are possible?
A: The most common combination is hard ABS/PP/PC + soft TPE/TPR. We can also provide two-color hard plastic + hard plastic combinations upon request, supporting different hardness, color, and transparency settings.
Q: Can the product achieve waterproof or anti-slip effects?
A: Yes. The soft plastic overlay itself has anti-slip, shock-absorbing, and sealing properties. With a reasonable structure, it can achieve light waterproofing and dustproofing, making it particularly suitable for handheld and outdoor products.
Q: Can you handle the development of secondary molding molds?
A: Absolutely. Kinghe provides a one-stop service from mold design to mold manufacturing, primary injection molding, secondary molding, and mass production. Customers only need to provide their product requirements.
Kinghe focuses on high-quality precision molding, dedicated to providing stable, reliable, and high-end secondary molding services to global customers. We continuously optimize our process capabilities, improve product yield, and enhance structural reliability, ensuring that every product using secondary molding combines a comfortable feel, a premium appearance, and durable quality. We are committed to putting customer needs first and aiming for long-term win-win cooperation. We empower our partners with professional technology and stable mass production capabilities, helping them create more competitive and market-received high-end plastic products and become a precision molding manufacturing brand trusted by global customers.
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No. 208, Hengjie East Road, Hengjie Town, Haishu District, Ningbo City, Zhejiang Province, China
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