Overmolding Services
Advanced Protection for Electronic Assemblies
PICA Manufacturing Solutions provides advanced overmolding services to enhance the durability, protection, and functionality of electronic assemblies. Using durable thermoplastic or elastomeric materials, our overmolding process encapsulates PCBs, connectors, and wire harnesses—creating a sealed, ruggedized layer that protects against moisture, vibration, strain, and environmental exposure.
By integrating overmolded electronics into your design, you can reduce the need for secondary enclosures, streamline product assembly, and improve long-term reliability in demanding applications. From functional prototypes to high-volume runs, PICA delivers custom solutions built for the mechanical and environmental challenges of modern electronic systems.
Why Choose PICA for Overmolding?
Custom Solutions – Tailored overmolding for flex circuits, connectors, cables, and user interfaces.
Material Expertise – Thermoplastics and elastomers selected for durability, ergonomics, and compliance.
Precision Tooling – High-quality molds engineered to support complex geometries and repeatability.
Scalable Production – From prototype validation to high-volume manufacturing runs.
Integration Ready – Overmolding designed to align seamlessly with PCB and electronic assemblies.
Overmolding Capabilities (Highlights)
Thermoplastic and elastomeric overmolding
Direct overmolding onto PCBs, flex circuits, and wire harnesses
Multi-material and complex geometry support
Strain relief for cable assemblies
Ergonomic and functional enhancements for user interfaces
Benefits of Overmolding
Enhanced Protection
Encapsulation shields electronics from moisture, vibration, mechanical stress, and environmental exposure.
Improved Reliability
By sealing sensitive areas, overmolding increases durability and reduces failure rates in harsh applications.
Design Flexibility
Supports complex geometries, ergonomic enhancements, and multi-material designs tailored to user needs.
Reduced Assembly Costs
Eliminates secondary housings or enclosures, simplifying builds and lowering overall system costs.
Better User Experience
Overmolding improves ergonomics, grip, and product aesthetics, enhancing functionality and usability.
Markets & Applications
Medical Devices
Sealed, biocompatible assemblies for portable monitors, sensors, and patient-safe interfaces.
Automotive & Transportation
Durable overmolded harnesses, connectors, and modules resistant to vibration and environmental stress.
Industrial Equipment
Ruggedized electronics for robotics, automation, and heavy-duty environments.
Consumer Electronics
Custom grips, enclosures, and strain-relieved cables that improve usability and durability.
Defense & Aerospace
Encapsulated assemblies that withstand extreme conditions and ensure mission-critical reliability.
The blogs featured below expand on this page’s content, offering detailed insights into specific design, manufacturing, and application topics that provide added relevance and deeper context for engineers and decision-makers.
Request Your PICAKit Today
We want you to take a look at what we can produce for you by offering you a PICAKit which includes a variety of flexible pcb, shields, & flat flexible cables.
