Injection Overmolding
Precision Overmolding for Integrated Thermoplastic Assemblies
Mercury Plastics delivers injection overmolding solutions that simplify assemblies, improve performance, and eliminate traditional joining methods. By molding thermoplastic materials directly over tubing, profiles, or components, we create robust, leak-free connections and integrated features without adhesives, clamps, or secondary operations.
Water Line - Click Connex
Water Line - Click Connex
Water Heater Dip Tube
Refrigeration
Refrigeration
Ice Maker Fill Assembly
Ice Maker Fill Assembly
Ice Maker Fill Assembly
Faucet Waterway
Faucet Piece
Drain Tube
What is Injection Overmolding?
A Better Way to Join and Finish Thermoplastic Components
Injection overmolding is a process in which molten thermoplastic material is molded directly over an existing substrate, such as tubing, extrusion profiles, or molded parts. This creates a permanent mechanical bond and allows functional features to be added precisely where needed.
With Mercury Plastics’ injection overmolding capabilities, customers can:
- Create leak-free joints without adhesives, clamps, crimping, or heat sealing
- Add end details, ports, brackets, or mounting features in a single operation
- Reduce part count, assembly time, and failure points
- Improve durability, consistency, and long-term performance
Injection overmolding enables cleaner designs, stronger connections, and more reliable systems across demanding applications.
Injection Overmolding Applications
Mercury Plastics supports a wide range of injection overmolding applications where performance, reliability, and manufacturability are critical.
Typical applications include:
- Overmolded tube connections and end fittings
- Integrated ports, junctions, and manifolds
- Structural and functional features molded onto tubing or profiles
- Fluid conveyance and plumbing assemblies requiring leak-free performance
Our teams work closely with customers to ensure proper material selection, tool design, and process control for consistent results at scale.
Core Thermoplastic Processes Under One Roof
Mercury Plastics is unique in offering all plastics and e-beam capabilities under one roof: extrusion, Air-Core® molding, forming, fabrication, injection overmolding, industrial-polymer modification, and bioburden reduction. This eliminates fragmentation and enables faster iterations from concept to finished part.
Our engineering teams frequently combine injection overmolding with:
Extrusion
Overmolding adds functional features and connection points to extruded profiles and tubing, reducing secondary operations and assembly complexity.
Air-Core® Molding
Forming & Fabrication
Formed tubing assemblies can be overmolded to add robust joints, transitions, or mounting features without fittings or adhesives.
Electron Beam Crosslinking
Crosslinking improves the thermal, chemical, and mechanical performance of compatible materials, enhancing the durability and long-term reliability of overmolded assemblies.
Engineering Support from Start to Finish
Our engineers collaborate with you early—using SolidWorks®, Moldflow®, FEA, prototyping, and our in-house machine shop—to optimize manufacturability, reduce cost, and achieve performance targets
Why Choose Mercury Plastics?
A Partner for Complex, Multi-Step Thermoplastic Programs
Integrated Manufacturing Expertise
Injection overmolding is part of a broader system that includes extrusion, molding, forming, fabrication, and crosslinking. This integration reduces risk, shortens development cycles, and improves overall program outcomes.
Engineering Led Solutions
Our teams focus on solving functional challenges, not just producing parts. From joint integrity to material compatibility, we help customers achieve performance targets efficiently.
High-Performance Results
Overmolded assemblies deliver improved reliability, reduced leak paths, and consistent performance in demanding environments.
ISO-Certified Quality
Mercury Plastics operates under an ISO 9001:2015 registered Quality Management System, ensuring repeatability and control for critical applications.
Thermoplastics Resources & Education
Get Started with Mercury Plastics
Discover how Mercury Plastics can help you improve product performance, reduce costs, and accelerate time-to-market.