Move Over, Metal: How to Successfully Overmold Thermoplastic Composites

October 06, 2020

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Snowboard binding made by Injection Overmolding

Continuous fiber reinforced thermoplastic (CFRTP) composites are emerging as the next generation of composite materials for highly engineered and metal replacement applications. Overmolding these composites integrates tapes or laminates into traditional processes, such as injection and compression molding with long-fiber thermoplastics, to create locally-reinforced components. This process combines the design flexibility and fast cycle times of traditional molding with the strength, stiffness, and light-weighting benefits that composites offer. The secret to success lies in understanding the process, geometries, matrices, and materials used.

Primary Topics:

  • Material selection for overmolding - compare and contrast
  • Basics of injection overmolding with CFRTP and LFT materials
  • Performance comparisons
  • Application considerations and successes


Brent DeSilva
Advanced Application Development and Technical Service Engineer, Avient Corporation
Brent DeSilva leads process troubleshooting, optimization, and automation for fiber-reinforced carbon and glass fiber composite profiles at Avient. He's responsible for process optimization of dozens of product lines across two manufacturing facilities. Prior to working with Avient, he spent almost three years at Lockheed Martin in various technology roles working with GPS satellites and weapon systems.

Steve Ouendag
Application Development and Technical Service Manager, Avient Corporation
Steve Ouendag is Application Development & Technical Service Manager for long-fiber reinforced thermoplastic composites at Avient. He has over 20 years of industry expertise assisting OEMs and processors in maximizing the benefits of structural thermoplastic materials. Steve holds a Bachelor of Science degree in plastics engineering from Ferris State University.