Overmolding looks simple: place one material over another, protect the assembly, move on. For RF devices, it's one of the most demanding parts of development — a complex interface between mechanical performance, material chemistry, manufacturability, and radio-frequency behavior, where the wrong material or geometry can detune an antenna without anyone noticing until validation. This article covers what makes RF overmolding different, where design decisions need to start, and how to catch the failures that only show up once you move from prototype to production.
