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What is insert molding?

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Insert molding is a manufacturing process involving inserts to create a cavity in a mold. Inserts can be made from a variety of materials, including metals, or ceramics. if the insert is plastics, we also called insert molding and overmolding. This process is typically used to produce small metal parts with intricate details.

Insert molding is an injection molding manufacturing process in which a mold is filled with a pre-prepared insert of different material and then injected with plastic resin, and the molten material is joined with the insert and cured to make an integrated product.

What is Insert Molding Process?

This plastic molding manufacturing process is the same as the injection molding process and uses the same injection molding machine to inject the molten material into the plastic injection mold, then the plastic cures through a cooling system, the press opens and the injection molded part is discharged.

Insert molding uses the same materials as the injection molding process, except that the metal is added to the mold before the injection mold is closed.

By using the same thermoplastic. The same mold steel, the same mold construction, and the same injection molding machine may sometimes require the use of a vertical injection molding machine for certain special cases.

Some injection molders use vertical injection molding machines that use gravity to aid in the insertion process by holding the insert in place during mold closure. Insertion in place during mold closure.

What is the purpose of metal inserts in products?

Metal inserts in injection molded products are used to improve the working strength of plastic products and increase the function of the products (such as improving the electrical conductivity of the products or facilitating the connection between the products and other parts, etc.).

Features of insert injection molding process

  • The combination of the ease of molding and bending of resin and the rigidity, strength, and heat resistance of metal can make complex and delicate metal-plastic integrated products.
  • In particular, the combination of the insulating mechanical properties of resin and the electrical conductivity of metal enables the insert molded parts products to meet the basic functions of electrical products.
  • The prior molding combination of multiple threaded inserts makes the post-engineering of the product unit combination more rational.
  • Insert products are not limited to metal, but also include cloth, paper, wire, plastic, glass, wood, wire coils, electrical parts, etc.
  • For rigid molded products and flexible molded products on rubber gaskets, the complex work of arranging the sealing coils can be eliminated by injection molding on the substrate to make integrated products, making it easier to automate the post-process assembly.
  • Since the molten material is joined to the metal insert, the gap between the metal parts insert can be designed to be narrower than that of the press-in molding method, and the composite product can be molded with higher reliability.
  • Select the appropriate resin and molding conditions, even for products that are prone to deformation and breakage (such as glass, coils, electrical parts, etc.), the resin can be sealed and fixed.
  • Choose the appropriate mold structure, the inserted products can also be completely sealed into the resin.
  • The combination of the vertical injection molding machine, robot, and overmolding insert molding device can realize automatic production.
  • After the insert is molded parts, it can be made into products with hollow grooves by removing the core holes.

What are the advantages of insert injection molding?

  • Reduced post-molding assembly
  • Saves assembly and labor costs by allowing many sizes and types of inserts to be placed directly into the mold cavity before plastic injection, thus avoiding secondary operations and providing a solid fit between insert and plastic.
  • Size and weight reduction
  • Increased demand from several industries for metal to plastic parts due to size and weight
  • Metal to plastic conversion can improve part efficiency in a variety of ways
  • Reduced part weight
  • Reduces production costs
  • Avoid corrosion
  • Increased durability
  • Enables designers to integrate features that make parts stronger, more durable, and more reliable than native plastic areas.
  • Enhances product design
  • Allows integration of features not possible with plastics alone
  • Increases design flexibility
  • Stronger and more durable part designs

Insert molding operation

Manual insert loading

In a manual insert loading operation, the operator loads the insert into the mold during the molding process. Manual loading is common for small volume applications or when there are several different inserts in one part.

Manual loading is simple and effective for small volume applications. With a full-time operator, manual loading gives you the option to perform detailed part inspection, assembly, packaging, or assembly at little to no additional cost.

However, for higher volume projects, manually loading inserts can become too expensive or inefficient.

Automated loading inserts

Automated equipment can be used to reduce the unit cost of parts, and cost savings are realized in two ways.

First, the injection molder‘s operating costs will be reduced because there will no longer be a full-time operator on the machine.

Second, because the robotic system can load inserts into the mold faster than an operator, you can produce more parts per hour, resulting in a lower unit price.

Summary

Through this article, we have learned about the knowledge points related to insert molding, the need to preheat the insert in advance when insert molding, and the problems related to stress concentration, cracking, and firmness around the insert tend to occur.

In the actual project production, it is recommended to verify the relevant experience of the injection molding factory, so that we can make plans for the possible problems to ensure the smooth implementation of the project.

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