As electronic products become smaller, tougher, and more reliable, overmolding PCBs has become a go-to solution for industries ranging from automotive to medical wearables. This process offers superior protection against moisture, vibration, chemicals, and physical impact—ensuring long-term performance in demanding environments. However, while overmolding adds real value, many engineers and purchasing managers are still unsure about the cost structure behind it. In this guide, we break down what really influences overmolded PCB pricing in 2025, provide actual USD cost examples, and share tips to help you avoid hidden charges and make smarter sourcing decisions.
1. Core Factors Influencing Overmolding PCB Costs
1.1 PCB Type and Complexity
The type of PCB being overmolded plays a significant role in cost. A simple single-sided FR4 board may only add $0.50–$1.00 per unit in overmolding costs, while a multilayer rigid-flex board with 3D contours could raise that cost to $3.00–$5.00 per unit, especially in low volumes.
1.2 Overmolding Material Selection
Materials like TPU (thermoplastic polyurethane) and TPE (thermoplastic elastomer) are commonly used. On average:
- TPU: $6–$10/kg
- TPE: $4–$7/kg
- Liquid Silicone Rubber (LSR): $12–$20/kg
For example, overmolding a small sensor module using TPU may add $0.80–$1.50/unit in material costs depending on the volume and wall thickness.
1.3 Mold Tooling and Setup Fees
Custom molds are often the largest upfront cost:
- Simple mold: $800–$1,500
- Complex multi-cavity mold: $2,500–$5,000+
While tooling is a one-time cost, it must be factored into small projects. For instance, a 500-piece run with a $2,500 mold adds $5.00 per unit just from tooling.
1.4 Volume and Batch Size
Overmolding costs dramatically decrease with higher quantities:
- 10 units (prototype): $5.50–$9.00/unit
- 100 units: $3.50–$5.00/unit
- 1,000 units: $1.20–$2.80/unit
- 10,000 units: $0.70–$1.20/unit
Larger runs benefit from tooling amortization and faster mold cycles.
1.5 Part Size, Geometry & Thickness
A larger or more complex design increases both material usage and cycle time. For example:
- Small wearable PCB (25x25mm): $1.00–$1.80/unit
- Automotive sensor housing (60x60mm): $3.50–$5.00/unit
Hidden costs can catch buyers off guard:
- Mold maintenance: Up to $200/year for high-use molds
- Design revisions: Mold rework may cost $300–$1,000
- Shipping heavy molds internationally can add $100–$300
- Assembly delays caused by incorrect tolerances or poor venting designs
Always ask about lifetime mold support and engineering services upfront.
3. Global Overmolding PCB Cost Comparison (2025)
| Region | Typical Unit Cost (1,000 pcs) | Tooling Fees |
| China | $1.20–$2.80/unit | $800–$2,000 |
| USA | $2.50–$5.00/unit | $2,000–$5,000 |
| Germany/EU | $3.50–$6.00/unit | $2,500–$6,000 |
| Southeast Asia | $1.00–$2.50/unit | $1,000–$3,000 |
China and Southeast Asia remain the most cost-effective for mid to high-volume orders, especially when lead times are flexible.
4. Cost Differences Across Applications
Automotive (IP67/IP69K protection):
$3.00–$6.00/unit, high material durability required
Medical (biocompatible & cleanroom molding):
$4.00–$7.50/unit, stricter regulatory demands
Consumer Electronics (USB, chargers):
$0.80–$2.00/unit, optimized for mass production
Industrial IoT Devices (ruggedized enclosures):
$2.50–$5.00/unit, thick molding and connectors
5. Real Price Examples in 2025
Overmolded USB PCB (1,000 pcs)
- Mold: $1,200
- Overmold cost/unit: $1.30
- Total cost/unit (including mold): ~$2.50
Automotive Sensor PCB (5,000 pcs)
- Mold: $2,800
- Overmold cost/unit: $3.80
- Total cost/unit (including mold): ~$4.36
Wearable Medical PCB (500 pcs)
- Mold: $2,000
- Overmold cost/unit: $5.20
- Total cost/unit: ~$9.20
6. How to Reduce Overmolded PCB Costs Without Sacrificing Quality
- Use standard mold bases or collaborate with suppliers offering mold-sharing
- Simplify your PCB outline and reduce unnecessary protrusions
- Choose cost-efficient materials like TPE over silicone if specs allow
- Consolidate orders to reach economies of scale
- Get a free DFM review before finalizing mold design
7. Why Choose KingSunPCB for Overmolding PCB Services
At KingSunPCB, we offer:
- One-stop service: PCB fabrication + overmolding under one roof
- Free mold consultation and transparent pricing
- Competitive overmolding rates: as low as $0.85/unit for 10K+ orders
- Fast turnaround: typical lead time 7–14 days
Our overmolded PCBs are used in automotive connectors, outdoor sensors, smart wearables, and more. Contact us to request a custom quote today.
8. Conclusion
Overmolding adds significant value to PCBs—but only when you understand the full cost picture. By factoring in materials, mold setup, global pricing, and hidden fees, you can make smarter decisions for your project. Whether you’re prototyping or scaling production, KingSunPCB is ready to help you achieve the right balance of protection, performance, and price.