Two-Color Injection Molded Comfort-Grip Cup Handle

A cup handle looks simple until two materials, assembly fit and daily handling all have to work together. The rigid portion must carry the load and hold its shape. The contact area should feel comfortable in the hand. Both materials also need to meet cleanly, without an obvious step, loose insert or secondary bonding operation.

This pink handle uses a rigid PP structure with a soft-touch TPE area. It is produced through a two-material molding process for drinkware and everyday-use products. The design shows why the part structure, material pairing and tooling sequence need to be planned together before mold construction begins.

Why Use PP and TPE in One Handle?

PP gives the handle its basic shape and structural support while keeping the part relatively light. TPE is placed where the user touches or grips the handle, adding a softer surface and more friction than the rigid substrate alone. The two materials do different jobs, so the design should not treat the TPE as decoration applied after the main part is complete.

The interface between PP and TPE needs enough area and suitable geometry for stable retention. Material compatibility, surface texture, local thickness and the flow path of the second material all affect the finished bond. Where necessary, mechanical locking features can be added to support the material interface rather than relying only on adhesion.

Tooling Has to Account for Two Molding Stages

In a two-color or overmolding process, the first shot creates the rigid substrate and the second shot adds the soft material. The tool and transfer method must keep the first component located accurately before the second cavity fills. If the substrate shifts, the soft-touch boundary can become uneven or the second material can flash into areas that should remain clean.

Gate position, venting and shutoff design matter at both stages. The PP shot needs to fill the full handle without creating avoidable deformation. The TPE shot needs to reach the end of its contact area while maintaining a controlled edge around the visible interface. Early DFM review should also check draft, radii, wall transitions and ejection so that the part can leave the mold without marking its gripping surfaces.

Shape and Assembly Still Come First

A soft surface cannot correct a weak handle geometry. The mounting ends, internal supports and transition into the curved grip need to carry the expected load before the TPE layer is considered. The part should also locate consistently against the mating cup or bracket so that assembly forces do not twist the handle or concentrate stress at one fastening point.

The images show a smooth outer profile, reinforced mounting ends and a defined soft-touch insert area. These features are reviewed together because a change to the exterior can affect wall thickness, tooling access or the available space for internal support.

Coordinating the Handle With the Tumbler Lid

Drinkware programs often include several molded components rather than a single isolated part. A handle, lid, closure, seal carrier and decorative components may use different materials and tooling, but they still share color, fit and appearance requirements. Managing these parts under one development workflow makes it easier to review interfaces and production samples together.

The second video shows an injection molded tumbler lid from the same broader product category. Its geometry, moving features and assembly interfaces are different from the handle, yet the manufacturing questions are familiar: material selection, dimensional control, visible-surface quality and repeatable fit with mating components.

What to Confirm Before Starting a Double-Shot Handle Mold

• Which areas carry the structural load, and which areas require a soft-touch surface?
• Are the selected PP and TPE grades suitable for the intended bonding method?
• How will the first-shot substrate be located during the second molding stage?
• Where should gates, vents and visible material boundaries be placed?
• What assembly dimensions and appearance points need to be checked during trials?

Kunshan Maifeng Precision Industry Co., Ltd. supports product structure review, custom mold design and manufacturing, two-material injection molding and plastic part assembly. Drawings, material requirements, expected volume and mating-part information give the engineering team a practical basis for reviewing a new handle or drinkware component.

Company Profile

About Us

Kunshan Maifeng Precision Industry Co., Ltd. (MIF) has an investment of RMB 35 million and an independent factory of more than 5,000 m². The company operates 36 single- and dual-color injection molding machines from 90 to 700 tons, together with more than 50 sets of mold manufacturing and processing equipment. Our service, management and production team includes over 100 people.

Our parent company was established in 2008. We provide product design, mold design and manufacturing, injection molding and product assembly services for custom plastic parts, supporting both domestic and international customers.

1. Product Design
Product structure design and optimization based on customer drawings and samples.

2. Mold Design
Mold design developed around product geometry, material and production requirements.

3. Mold Manufacturing
Machining, polishing, fitting and assembly for custom injection molds.

4. Injection Molding
Single- and dual-color injection molding for project and order requirements.

5. Product Assembly
Supporting assembly services for molded plastic components.