Overmoulding
Precision overmoulding onto medical tubing
What is overmoulding
Overmoulding is the process of bonding a second material onto a base. This results in a single, integrated component without the need for adhesives or secondary assembly.
This approach is widely used in medical device applications where performance, precision and durability are critical. By combining multiple materials into a single part, overmoulding enables improved functionality, more ergonomic designs and greater design flexibility.
Key Benefits of Overmoulding Include:
- Eliminates secondary assembly and reduces component count
- Improves bonding strength and long-term durability
- Enhances device ergonomics and overall performance
- Enables complex, multi-material designs and fine features
- Supports reliable, repeatable manufacturing at scale
- Reduces production costs and variability
- Reduces risk of part failure
At Lawrence Engineering, we specialise in medical overmoulding onto extrusions, metal components and hypo-tubes for medical devices. This has, and continues to be, a key area of focus for many of our clients.
From in-house design and tooling to cleanroom production, we provide seamless, end-to-end support for your overmoulding requirements
How can we assist
Overmoulding is widely used across a wide range of medical applications including
- Catheter assemblies
- Minimally invasive delivery systems
- Handheld diagnostic and surgical tools
- Sheath or introducer systems
- IV tubing and access ports
- Tube-end features such as strain reliefs and anchor points
Our team supports you at every stage, from design through to full-scale production, ensuring optimal performance, manufacturability and regulatory compliance.
By partnering with Lawrence Engineering, you gain a single, trusted supplier for complex medical overmoulding solutions
Design
Successful overmoulding starts with optimised design and process expertise. Using our experience in material behaviour, mould design, and mould flow analysis, we develop solutions that support consistent filling, dimensional accuracy, and repeatable manufacturing performance.
Our in-house design team provides comprehensive
support to ensure consistent quality and manufacturability.
Services include:
- Design for manufacture (DFM) to ensure that you have the best mould option depending on the shape of the product, the quantities expected, and the material to be processed.
- Mould flow analysis to optimise geometry and
ensure efficient, defect-free manufacturability. - Expertise in critical design features like pinch-offs
for clean, flash-free parts. - Advanced multi-lumen design, supporting complex
designs including bifurcation and trifurcation.
Injection Mould Tooling & Inserts
Once your component design is finalised, we move to tooling. Whether it’s a prototype or full production tooling, we have the in-house capability to deliver quickly and cost-effectively.
We also offer tool inserts for use in our range of in-house mould bases which significantly reduces upfront costs and leadtimes when manufacturing takes place in our cleanroom facility.
Precision Core Pins for Overmoulding
Core pins are a critical part of the overmoulding process. At Lawrence Engineering, we specialise in the design and manufacture of core pins that enable the highest standards of part quality, performance, and repeatability.
Our capabilities include:
- Manufacturing to an accuracy of ±0.001mm.
- Producing core pins ranging from simple to complex
shapes, including fully bespoke designs. - Expertise in working with a wide range of materials,
and material selection for core pins. For example,
nitinol which enables the pins to “flex” or “form” into
the desired trajectory when tube and core pins are
loaded into the cavity insert.
ISO 13485 Cleanroom Production
Overmoulding is carried out in our Class 8 cleanroom, supported by a QMS certified to ISO 13485. Our validated manufacturing processes ensure consistent, repeatable production with full traceability, from low-volume prototypes through to high-volume manufacture.
Our metrology and testing capabilities, ensure components meet stringent quality and regulatory requirements, including ISO 80369-7 Luer compliance. We also offer sub-assembly services and seamless product transfers, as required.
Precision, Trust and Partnership
We work closely with our customers to deliver reliable, high-performance overmoulding solutions. Discover how our partnership with Renishaw Neuro Solutions enabled the successful delivery of a critical medical device component.
Read Case Study here.
Your Partner in Medical Overmoulding
Whether you are developing a new device or optimising an existing design, overmoulding can unlock improved performance, usability and manufacturing efficiency.
With specialist expertise in medical overmoulding, advanced tooling capabilities and cleanroom production, Lawrence Engineering is uniquely positioned to support even the most demanding applications.
Contact our team today to discuss your project and discover how we can support your overmoulding requirements.