Relevance and Considerations for Plastic Injection Molding of Metal Inserts

Insert Molding

Insert molding is the process of molding or forming a plastic part around other non-plastic parts or inserts. The inserted component is usually a simple object, such as a thread or rod, but in some cases the inserted component may be as complex as a battery or motor.

In addition, Insert Molding combines metals and plastics, or multiple materials and components, into a single unit. The process utilizes engineering plastics to improve wear resistance, tensile strength and weight reduction, and metallic materials to improve strength and electrical conductivity. 

Insert molding process

XY-GLOBAL uses high-quality molding machines designed for the insert molding process. The insert molding process requires extremely tight tolerances to ensure proper molding of the plastic part being created. Even the slightest deviation of a fraction of a millimeter can lead to the ultimate failure of the molding process. Our state-of-the-art insert molding equipment can meet your most exacting specifications.

Insert Injection Molding Benefits

Metal inserts and bushings are commonly used for reinforcing the mechanical properties of the plastic parts or thermoplastic elastomer products that are created through the insert injection molding process. Insert molding provides a number of benefits that will improve your company’s processes all the way down to its bottom line. Some of the benefits of insert injection molding, include:

●   Improves component reliability

●   Improved strength & structure

●   Reduces assembly and labor costs

●   Reduces the size & weight of the part

●   Enhanced design flexibility

Insert Injection Materials

Our insert molding machines and advanced quality equipment allow us to quickly adapt to the constant advancements throughout the industry. Improvements in polymer technology and molding processes have opened the door to new and exciting products and processes. We welcome these advances as we strive to provide our customers with the most advanced, alternative insert molding options available. We offer insert molding materials for most thermoplastics.

Applications and Uses for Injection Molded Inserts

Metal inserts for insert molding come directly from insert injection materials and are often used in a wide range of industries, including: aerospace, medical, defense, electronics, industrial and consumer markets. Applications of metal inserts for plastic parts, including

▶  Screws

▶  Studs 

▶  Clips

▶  Spring contacts 

▶  Pins

▶  Surface mounted pads 

And more......

Insert Molding vs. Overmolding

Insert molding and overmolding are two distinct processes that produce their own unique types of products. The overmolding process involves encapsulating one material over a second material. The base layer is first molded and additional layers of plastic are molded over and around the original part. This produces a single finished product. Overmolding creates a strong finished product with a long life and enhanced safety features.

In contrast, insert molding involves injecting inserted injection material into the mold cavity prior to injection molding of the plastic. The resulting product is a single piece with the insert encased in plastic. Insert molding offers a fast and cost-effective assembly process that produces parts of reduced size and weight.

Considerations for insert molding

XY-GLOBAL's experienced staff are experts in the insert molding process. They have the ability to take insert injection materials and create plastic injection inserts from these materials. However, there are certain factors that should be considered before making a final decision regarding the insert molding process. The cost of insert molding must be weighed, including the cost of the insert and the mold. The inserts themselves also need to be able to withstand the injection molding process, as some stresses and temperatures can damage them. Other factors that should be considered include

●   Methods of holding the insert during the molding process

●   Bump or groove that provides additional holding force within the molded part

●   Understanding which specific parts and techniques are combined into a single part during the insert molding process.

Contact XY-GLOBAL today

Contact us to learn more about our insert injection molding capabilities for creating plastic parts and metal inserts, or to request a quote today.