Thermoplastic Injection Molding
What is Insert Injection Molding?
Insert injection molding entails encasing a pre-made component within molten resin to create a final product. Typically, the inserted component is straightforward, such as a knife blade or surgical tube, though sometimes it can be as intricate as a battery or motor.
This process, beneficial for enhancing component strength and reliability, reduces costs and production time by eliminating secondary operations like soldering, connectors, and adhesives. It involves molding plastic around a diverse range of materials, usually simple metal objects like nuts or threaded rods. However, it's versatile enough to encompass ceramics, other plastics, motors, threaded bushings, batteries, or warning labels within the injection-molded part
What is the Insert Molding Process?
Insert molding initiates by placing the insert into a specifically machined mold designed to accommodate it seamlessly. Once the insert is in place, the mold is closed, and the injection of molten plastic begins, following the same procedure as regular injection molding. After cooling, the integrated part is ejected, firmly combining the insert within the plastic component. Our expertise at Toolingsun extends to various insert options, and our specialists can guide your project from design to realization."
"Our suite of plastic injection molding services includes insert molding among other specialized techniques. Utilizing advanced molding machines, we ensure precise tolerances for optimal plastic part formation. Collaborating with trusted vendors, we source high-quality metal inserts, and if needed, we accommodate customer-supplied inserts to meet your project specifications."
Metal Screw In Type: For enhanced strength beyond the base plastic, we utilize metal screw-in type inserts. These inserts allow for repeated unscrewing of metal screws or bolts, offering robust support within the component.
Plastic Pre-Molded: When assembly demands various properties of plastics or to maintain simplicity in the molding tool, a separate injection molding serves as an insert. This approach avoids complicating the primary molding tool, ensuring efficiency.
Perforated Plate Inserts: Specially designed inserts featuring a perforated base plate facilitate male or female threading. Commonly applied in the GRP Industry to achieve specific threading requirements.
Bearing Inserts: Through the insertion of specialized metal inserts (e.g., Brass, Gunmetal) within the molding process, the need for post-molding assembly is eliminated. These inserts offer robust support and act as a strong key to the base plastic.
Continuous Film: A technique originating from the packaging industry, where pre-printed plastic film is integrated into the injection molding process. This method is utilized to create molded articles like biscuit and cracker boxes.
Decorative Labels: Predominantly utilized in the injection molding process by the packaging industry. Individual pre-printed decorative labels are robotically placed into the mold during each machine cycle, aiding adhesion and enhancing the aesthetics of the final product.
RF Shielding: Primarily applied in the Glass Reinforced Plastics (GRP) industry, this method establishes a shielding barrier against radio frequency transmission. Incorporating a matrix of fine metal filament into GRP molding ensures effective shielding against RF interference.
Out-sert Molding: Involves using larger press-tooled metal plates as inserts within an injection-molding tool. By incorporating plastic materials onto these metal plates, the method ensures rigidity from the metal and the desirable properties of plastic materials for applications like VCR and camera chassis plates.
Typical Materials Used
Most thermoplastics can be processed with the use of Inserts. The table below lists some of the commonly used materials.
Acrylonitrile Butadiene Styrene ABS
Nylons(Polyamides) PA
Polycarbonate PC
Polypropylene PP
Polystyrene (General Purpose) GPPS
What are the Benefits of Insert Molding?
Opting for insert injection molding over secondary insertion processes presents two primary advantages. Firstly, while insert molding may initially incur higher costs due to increased manpower, it eliminates the need for post-processing insertion, resulting in significant time and cost savings. The integrated nature of inserts during molding mitigates the structural instability that secondary insertions may cause, ensuring consistent alignment and accuracy for parts requiring multiple components like threaded bushings.
Secondly, insert molding ensures structural stability by directly integrating components into the plastic part, unlike post-molding insertion methods that could compromise stability. This process not only reduces manual labor and associated costs but also guarantees consistent alignment and accuracy. Additionally, insert molding creates stronger parts, especially beneficial for prototypes or full production runs due to its efficiency in producing durable and reliable components."
"Insert molding offers various advantages:
Assembly Elimination: Parts are manufactured all at once, negating the need for post-assembly.
Cost Reduction: Although initial costs may be higher, eliminating post-assembly usually offsets the expense.
Size and Weight Reduction: Plastic parts with integrated metal inserts tend to be lighter than all-metal counterparts.
Enhanced Reliability: Metal mold inserts ensure functional threads and reduce wear over the part's lifespan.
Improved Strength: The 'one-shot' process results in stronger parts compared to other molding methods like overmolding."
Insert Mold — Injection Molding Highlights
Swift quoting for molds and parts (offline quoting required for inserts via project manager)
Cost-effective, high-quality production with rapid turnaround times
Utilization of mold frame sharing technology
Online project management services
Seamless and hassle-free part modifications
Compatibility with a wide array of commercially available materials and surface finishes
Visit our plastic injection and CNC machining case studies page to explore how we've assisted customers with their projects.
Metal Insert Molding
A third benefit of utilizing insert injection molding is its ability to contribute to weight reduction. By incorporating inserts into injection-molded parts, it's possible to achieve the same functionality as an all-metal part but at a significantly reduced weight. This weight reduction is particularly beneficial in industries like automotive and aerospace where minimizing weight is a priority. Threaded rods, nuts, bushings, or specifically machined metal components can seamlessly integrate into plastic parts, offering flexibility in design.
Leveraging metal insert molding proves advantageous in sectors prioritizing weight reduction. The experts at Toolingsun possess extensive collective experience in insert molding techniques. Furthermore, our robust Computer Numerical Control (CNC) machine department specializes in crafting custom metal parts tailored to meet precise customer specifications for metal insert molding."
Are There Special Considerations for Insert Molding?
Support
Is the part design compatible with the insert? Sufficient material surrounding the insert is essential to ensure a secure fit. Thin walls surrounding the insert could lead to the insert breaking away from the rest of the part during production, testing, or utilization.
Temperature
Can the insert withstand the temperature involved in the injection molding process? It's crucial to consider the temperature compatibility of plastic inserts. The injection molding process involves high temperatures and pressure to shape plastic parts. Ensure that any insert can safely endure the temperature required to melt the plastic injection material. Inserts not designed for high temperatures may deform or entirely melt during the injection molding process. It's advisable to use plastic inserts with a higher melting point than the injected material to prevent issues.
Pressure
Can the insert withstand the pressure exerted during the injection molding process? The plastic injection molding procedure involves significant pressure. It's crucial that inserts possess the necessary durability to endure this pressure without cracking or deforming. The high temperature and pressure combination can potentially damage certain inserts, making it essential to assess their suitability before commencing the insert injection process.
Comparison: Insert Molding, Overmolding, and Injection Molding
Both overmolding and insert molding are methods aimed at integrating distinct parts into a unified component. Overmolding involves encasing a pre-existing part with a plastic layer in a two-step process, resulting in a cohesive single component. In contrast, insert molding achieves the same integration in a single step by combining a preformed insert with molten resin in a mold, seamlessly merging two separate parts.
While insert injection molding shares similarities with other molding techniques, it distinctly involves encapsulating a smaller part, such as a threaded rod or bushing, within the injected plastic resin, forming a singular part where the plastic surrounds the inserted material.
Overmolding and insert molding both fall under the umbrella of injection molding processes. Insert molding typically involves encapsulating a smaller part within the plastic resin, creating a single part. On the other hand, overmolding entails the injection molding of a plastic layer onto an existing plastic part, forming a unified component composed of two different plastic materials. For instance, a cordless drill housing might first be molded, followed by a secondary overmolding process to apply softer grips onto the main body, resulting in a single part composed of different plastics.
Why Choose us for Molded Inserts?
Extensive Choices
Access millions of potential material combinations, finishes, tolerances, markings, and certified options available for your order.
User-Friendly Experience
Receive your parts directly at your doorstep, avoiding the complexities of sourcing, managing projects, handling logistics, or arranging shipments.
Verified Network
Our certification includes ISO 9001:2015 and IATF16949,:2016, ensuring that only the most exceptional shops meeting stringent standards become our suppliers after a rigorous qualification
Comprehensive Manufacturing Services
Producing components for crucial applications demands swift delivery of top-quality products. Our services in insert-molded part or assembly manufacturing are geared towards aiding you in meeting your production objectives efficiently
- New project Development
- Prototyping
- Tooling and molds
- Precision Metal Stamping
- Machined Parts Process Conversion
- Insert Molding
- Overmolding
- Assembly
- Automation & Robotics
- Laser Processing
- Welding
- Manufacturing Services
- Specialty Services
What is the Process for Insert Molding — Plastic Injection Molding with us
Our quote form and mold frame sharing technology enables us to simplify and shorten both the quoting and tooling manufacturing process for plastic injection molding.
1, Send us your 3D drawing with the format of step, stp, x_t, pro-e .
2, Upon confirming your order, we initiate the export mold order process.
3, we will design the tooling 3D and review several times in our team.
3, You'll be provided with the 3D comprehensive mold design for your review and approval.
4, After your approval of the tooling 3D design, we begins builing your injection mold.
5, We proceed with sample testing and pilot production.
6, Finally, we deliver the completed tooling to your specified location.
Insert Molding Applications
There are many applications to insert molding. Such applications include:
- Auto industry components
- Industrial equipment components
- Medical devices
- Consumer products
- Electrical parts
We have the insert molding experience and expertise to deliver the complex parts your project requires. Request a quote today or contact us for full-service injection molding for your unique application.