Video: Overmolded Gaskets and Seals

Photo: Overmolded filter plates that combine, rubber, plastic, screen mesh, and metal compression limiters.

How Morgan Polymer Seals Achieves World-Class Overmolding

We manufacture high-performance rubber gaskets and seals for top automotive OEMs across the globe. While many seals are made entirely of rubber, some critical systems call for more advanced solutions. That’s where overmolding comes into play—a process we’ve perfected to deliver unmatched reliability and performance.

What Is Overmolding?

Overmolding is the process of combining two or more materials into a single, bonded component. It allows us to pair rubber with materials like metal or plastic to create seals that are stronger, more durable, and capable of withstanding extreme conditions.

This isn’t just about sticking materials together—it’s about engineering a seamless bond that enhances functionality without compromising quality.

Our Process: Precision at Every Step

It all starts with a rigid insert—such as a plastic carrier or metal bushing. These components are pre-loaded into custom trays, ensuring perfect alignment and placement. To double down on accuracy, we use automated video inspection systems that verify every insert before it reaches the mold.

Once in place, rubber is injected into the mold, flowing around and bonding to the insert. Depending on the design, we use mechanical bonding, chemical bonding, or both. The result is a robust, unified part that performs like no single material ever could.

Going Beyond Rubber

Some parts require even more complexity. In many cases, we overmold rubber onto a plastic carrier. These carriers serve as the structural backbone, especially in applications where dimensional stability is critical.

We also produce highly engineered components like filter plates, which combine rubber, plastic, and even nylon mesh in a single part. Using a blend of robotics and rotary press technology, we can mold with extreme precision while maximizing efficiency.

Click the video below to see this technology in action, and click “contact us” to reach a product specialist who can quote your program.