PCB Overmolding
Turn fragile PCB assemblies into sealed, overmolded modules that survive moisture, dust, vibration, and rough handling.
- Protect sensors, controllers, and LED modules with IP-rated overmolding
- One-piece, sealed housing with built-in strain relief and mounting features
- DFM + tooling + molding under one roof, from prototypes to mass production
PCB Overmolding Services
Kemal combines electronics-aware DFM, in-house tooling, and precise injection overmolding to protect your PCBAs in harsh, real-world environments. From first prototypes to stable mass production, we help you replace messy potting and fragile housings with clean, robust overmolded packages.
PCB Overmolding Capabilities
| Capabilities | Details |
|---|---|
|
Supported PCB types |
Rigid FR-4 boards, aluminum PCBs, rigid-flex modules, PCB + cable/connector assemblies |
|
Typical assembly size |
From small sensor boards to medium-size control and power modules |
|
Overmolding approach |
Single-material overmolding, insert overmolding around PCBAs, PCB + cable strain-relief overmolding |
|
Overmold materials |
Engineering thermoplastics (PC, PA6/PA66, PBT, PC+ABS, PPS, etc.) and selected TPE/TPU grades |
|
Tooling & engineering |
In-house mold design and build, DFM for PCB layouts, gate/vent design around components |
|
Production scale |
Prototype runs, pilot builds, and full mass production with documented process windows |
|
Quality & compliance |
ISO 9001 & ISO 13485 systems, FAI, CTQ inspection, support for IP/leak, thermal and vibration testing (per your plan) |
Why Electronics OEMs Choose Kemal for PCB Overmolding
DFM Support
We provide a free DFM report before cutting steel, reviewing your PCB layout, keep-out zones, sensitive areas, and target sealing requirements to flag risks early. You receive clear recommendations and options upfront, reducing trial loops and avoidable tooling changes. Redacted DFM samples can be shared upon request for customer review.
Predictable Lead Times
Tool design, mold making, trials, and PCB overmolding production are handled in-house, so schedules are not dependent on outsourced capacity. With our own equipment and planned production slots, we run a clear milestone flow from DFM to T0 and sample approval. Progress updates can be shared during the project to support internal planning and customer review.
ISO 9001 Quality System
We operate under an ISO 9001 quality management system to support PCB overmolding programs that require controlled documentation, lot traceability, and consistent inspection/release criteria. ISO 9001 certification and selected audit-ready record samples can be provided upon request for customer supplier qualification. For regulated programs, additional certifications can be supported when applicable.
Traceability & Change Control
We maintain lot-level traceability for PCB overmolding programs and manage drawing/CAD, tooling, material, and key process changes through a documented ECN/ECR workflow. Revisions are reviewed and approved before implementation, with records linked to samples and production lots to support fast issue isolation and corrective actions. Redacted traceability labels and ECN/ECR samples can be shared upon request for customer review.
Tooling & Fixturing for PCBAs
We design and build PCB overmolding tools with dedicated fixturing to locate the PCBA, connectors, and cables in a repeatable position before every shot. Keep-out zones and sealing boundaries are built into the tooling through proven locating and shut-off features, helping prevent shifting, flash in sensitive areas, and inconsistent sealing. Tooling/fixture visuals and redacted design snapshots can be shared upon request for customer review.
PCBA Protection & Handling
We handle PCBAs under a controlled workflow to reduce damage and ESD risk during overmolding. Boards are positioned with dedicated fixtures, protected in key areas, and checked at defined steps before and after molding to prevent handling-related defects and hidden failures. Shop-floor visuals of the handling/fixture setup can be shared upon request for customer review.
Design Guidelines for PCB Overmolding
Good PCB overmolding starts with the right design. We review your PCB assembly and overmold concept before cutting steel, so the board stays safe and the module meets your sealing targets.
Keep-out zones – Mark test pads, LEDs, buttons, connectors that must stay open.
Component layout – Avoid tall/heat-sensitive parts near gates and critical flow paths.
Interfaces – Define which connectors and LEDs must remain visible and how they seal.
Cables – Specify exit direction and bend radius so we can build proper strain relief into the overmold.
Comprehensive Plastic Part Services
We provide early-stage design for manufacturability (DFM) analysis to optimize wall thickness, draft angles, and gate placement. This helps identify risks upfront and reduces costly mold changes later.
From single- to multi-cavity and hot runner molds, we build tooling that matches your production needs. Steel selection and surface finishes ensure durability and precision over the mold’s lifetime.
We offer standard molding, insert molding, and overmolding options. Each run is monitored with scientific process controls and full batch traceability to guarantee consistent results.
Choose from painting, pad printing, laser marking, and UV coating. ABS is especially well-suited for surface finishes, making it ideal for branded housings and visible parts.
Every part goes through strict IQC, IPQC, and OQC processes. We provide dimensional reports and compliance documentation to meet international standards.
Assembly & Delivery
From sub-assemblies to custom packaging, we streamline the final steps before shipping. Global logistics support ensures your parts arrive efficiently and ready to use.
Our Customers
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FAQ's
What is the difference between PCB overmolding and potting?
Potting fills a shell with liquid compound; PCB overmolding forms a molded housing directly around the PCBA for a cleaner boundary, integrated features, and repeatable geometry.
Can you keep connectors, LEDs, and test pads exposed?
Yes. We define keep-out zones and build shut-offs into the tooling so functional interfaces remain accessible while the rest of the PCBA is protected.
Do you support PCBA overmolding with cable strain relief?
Yes. Cable exit direction, bend radius targets, and retention features are designed into the overmold to reduce pull-out and flex-fatigue risk.
What materials are used for PCB overmolding?
We support engineering thermoplastics and selected TPE/TPU grades; silicone overmolding is available when elastic sealing is required.
How do you prevent the PCBA from shifting during molding?
We design dedicated fixturing and locating features to hold the PCBA, connectors, and cables in a repeatable position for every shot.
What inspection or documentation can you provide?
FAI and CTQ-focused inspection, lot traceability, and documented change control are available based on program requirements.
Get a Quote for PCB Overmolding
Send your PCBA outline, keep-out zones, and target sealing requirements. We’ll confirm the overmolding route, materials, and tooling plan for production.
