About Insert Molding Process
As one process of injection molding, insert injection molding is the process of molding or forming plastic parts around other non-plastic parts or inserts. The inserted component is most commonly a simple object, such as a thread or rod, but in some cases, inserts can be as complex as a battery or motor.
Moreover, Insert molding combines metal and plastics or multiple combinations of materials and components into a single unit. The process uses engineering plastics for improved wear resistance, tensile strength and weight reduction, and using metallic materials for strength and conductivity.
Advantages of Insert Molding
A wide range of metal components can be used in the insert molding process, including screws, limiters, threaded fasteners, magnets, filtering screens, tubes, clips, mounting brackets, and more. These components can be stainless steel, brass, copper, aluminum, nickel, or bronze. Moxperts team will work with you to select the best combination of metal and plastic based on the part’s requirements.
Durability
It affords enhanced product design and manufacturing. The precision with which you can place inserts into a mold design cannot be achieved with other molding processes. In short, plastic parts with integrated components are much more robust and more reliable.
Light Weight
Plastic parts can be up to 50 percent lighter than their metal counterparts, which is one of the primary reasons many industries are turning to plastic molding for parts. From fuel efficiency to better ease-of-use for surgical instruments, lighter weight enhances performance and functionality.
Smaller in Size
The insert molding process allows the production of much smaller or thinner parts without sacrificing durability or performance. A simple example is vehicle components. Thinner door and console parts mean more room in the interior of the car.
Cost-saving Solution
Insert molding achieves cost savings in two ways. First, they allow the use of much cheaper materials. Also, molding production processes themselves are cost-effective. Insert molding is a one-step process. Unlike other types of molding, assembly and labor costs can be streamlined.
High Efficiency
Insert molding eliminates a second assembly step in the manufacturing process. The insertion of metal or other components is integrated with the molding step, so there is no need for a stand-alone task. It saves time and money associated with labor and specialized equipment for these processes.
Variety of Materials
Insert molding can use many different types of plastic resins in the process—these include thermoplastics, which are eco-friendly since you can recycle them. The most common thermoplastics are polyethylene, polystyrene, and nylon. These are all lightweight, durable, and ideal for consumer products to heavy-duty industrial ones.
Material options
Moxperts offer a wide variety of certified alloys for rapid insert injection molding services. If the material is not listed, feel free to contact us for a customized solution.
- Acetal polyoxymethylene (POM)
- Acrylonitrile butadiene styrene (ABS)
- Ethylene Propylene Diene Monomer Rubber (EPDM)
- Nylon 66 (PA66)
- Glass-filled, polyamide (PA-GF)
- High density polyethylene (HDPE)
- Low density polyethylene (LDPE)
- Liquid Crystal Polymer (LCP)
- Melt Processable Rubber (MPR)
- Polybutylene terephthalate (PBT)
- Polycarbonate (PC)
- Glass-filled polycarbonate (PC-GF)
- ABS polycarbonate (PC-ABS)
- Polyethylene terephthalate (PET)
- Polymethyl methacrylate (acrylic) (PMMA)
- Polyphenylene sulfide (PPS)
- Polypropylene (PP)
- Polyvinyl Chloride (PVC)
- Polystyrene (PS)
- Polystyrene +
- polyphenyl ethers (PS-PPE)
- Thermoplastic elastomer (TPE)
- Thermoplastic vulcanizates (TPV)
Prototype
Finishing Services
As molded
- Part number
- Logo
Standards for plastic injection molding surface finishes established by Society of Plastic Industry (SPI).
- Grade A: Glossy Injection Molding Surface Finish. Min. roughness: 0.012 μm. Mainly for Acrylic, PC.
- Grade B: Semi-Glossy Injection Molding Surface Finish. Min. roughness: 0.05 μm. Mainly for ABS, HDPE, Nylon, PP, Polystyrene.
- Grade C: Matte Injection Molding Surface Finish. Min. roughness: 0.35 μm. Mainly for ABS, HDPE, Nylon, PP, Polystyrene.
- Grade D: Textured Injection Molding Surface Finish. Min. roughness: 0.80 μm. Mainly for ABS, HDPE, Nylon, PP, Polystyrene, TPU.
