insert molding

Insert Molding metals and plastics together in a molded part, or multiple metals or materials molded together into a single molding part. we sometimes called metal insert molding or metal screw/brass insert molding, sometimes we call insert molding as over-molding. Insert molding (moulding) can be used in automobile, cooking ware, household equipment, instruments, devices, knobs, electrical components and more industrial, Insert molding is not only reducing assembly and labor costs but also better than assembly part, reduces the size and weight of the part, improves component reliability, and delivers improved part strength and structure with enhanced design flexibility.

Today over 90% of insert molding parts are come from China molding manufacturing, the most important thing is China has low labor cost and high-quality control, and another factor is China can do assembly all of your ending parts together and ship to you, we are professional in plastic mold making and plastic molding manufacturing over 18 years, we have strong engineering, mold maker team, quality control production, we can make your project from start to end, no matter normal molding, 2k injection molding, insert moulding (molding), medical plastic molding, automobile industrial, cosmetic injection molding parts, or home appliances injection molding.

The Process of insert moulding ( molding)

The process is same as injection molding process, and use same injection molding machine to inject molten raw material into a plastic mold – the plastic is then solidified by cooling systems- and then the press opens and the molded parts are ejected, one different is before mold close we need put the metals into the mold and start all of injection molding process as injection molding,

Insert molding uses the same materials as the injection molding process except the metal added into mold before mold close. For intense, the same thermoplastics are used. Same mold steel, same mold structure, same injection molding machine, maybe sometimes need to use vertical injection molding machine for some special case, but all are injection molding machines which are working on thermoplastics

Some injection Molding manufacturers use vertical/vertical injection molding presses that use gravity to help in the insert molding process by maintaining the insert in position during mold closing. Insert in position during mold closing.

Most vertical insert molding machines have a feature that utilizes multiple bottom mould halves to be used with a single cavity half. While one bottom half is molding with the cavity half, the other bottom is available to be loaded together with the metals and other inert molding components.

Since multiple Bottom halves make it possible for inserts to be placed in one bottom half while the other one is in the molding step, cycle time is reduced.

Below are some of the inert molding parts we made before. If you have any project that needs brass insert molding or any metal insert molding, send us your requirement for a quotation.

How the insert molding can improve your molding parts and solve your issues.

Insert molding can be a highly efficient alternative to the assembly of discrete parts using soldering, connectors, fasteners, or adhesives. Its benefits over such methods include:

Insert molding can be an extremely efficient alternative to the assembly of the device, fasteners, connectors, or adhesives. To list all of the advantages there are some benefits for molding part as below:

  1. Reduce molding parts size
    Since molding parts that have a metal insert molded together with plastics, so the part size can be designed smaller compare to assembly parts, and the part weight will be less than the assembly parts, this will reduce the material cost which means save the cost by the better result.
  2. Reduced assembly and labor costs
    Because insert molding made by a single shot but have two or more parts joint together in an ending molding parts, this reduces assembly and labor costs, only need a worker to put the insert part into the mold during the molding production, a single insert or multiple inserts can be molded in one shot, the more complex insert molding part than the more benefits with insert molding
  3. Increased reliability
    Insert molding is molded together by the plastic molding process. So every part tightly molds in thermoplastic, an insert molded component prevents part loosening, mismatch, misalignment, and other problems. The plastic resin provides improved against shock and vibration.
  4. Increased design flexibility
    As a designer should be appreciated that it is a molding process with insert molding. Because we have this insert molding process, the designers will e save time to think about how to assembly the part together. Hot to fasten the metal parts and plastic part tight together. How to save the place for other components, so the process to let them design jobs more efficient.
  5. Save injection molding cost and work more efficient
    When inserts are used during the moulding stage than standard injection molding machines sometimes make it more difficult for operators to put inserts into their correct place in the mold. Like some small metal parts or multiple metal parts or some insert parts are easy to drop done the floor when put the inserts molding into the mold, for this reason, vertical injection machines are most efficient, this will save lots of time and injection molding cost.

Looking for insert molding service for your business? Please contact us and send us your 3D drawing, and the requirement for quotation, we will send you the price with 24 hours, to work with us we will solve your issue with part design, mold making, massive production, and part assembly. Get a quote now.

What is precision plastic injection molding?

Normally tolerance on the plastic molding part is around 0.05-0.1mm, if the part tolerance requirement is about 0.01-0.03mm, that means this is precision plastic injection molding, to make high precision plastic injection molding parts, the first thing is making the precision injection mold, all of the mold components must have tolerance within 0.005-0.01mm, this is min requirement for high precision plastic injection mold after mold is completed finished, then take mold trial to verify the dimension according to 2D drawing requirement, to trial the mold and make stable tolerance, precision plastic injection mold is number one key point to making high precision molding parts, but not limited to this, you still need use high precision injection molding machine to produce the part, by this two min requirement we can make sure that we can make precision molding parts continually, there are few issues that we make still need to know for the precision plastic injection molding.

Plastic precision Connector

Plastic precision Connector-overmolding

Question I:

The determination of the structure of the precision plastic mold is the key, and the overall structure is the embodiment of the final effect of the product: the determination of the overall structure of the mold, the determination of the gate system, the determination of the ejection system and the determination of the water transportation system, and others should be conducive to the post-processing orientation of the product.

Question II:

What about the feeding problem? First of all, we will choose a reasonable injection scheme according to the structure, weight, volume, and cost of the product, which can meet the requirements of customers as well as the requirements of quality. Second, we will design in strict accordance with the injection design standards: the layout of the runner should be uniform, especially the size of the cross load surface of the main and sub runner, the shape and size of the gate.

Question III:

What about the ejection problem? Firstly, we will determine the ejection mode according to product orientation and structure. Secondly, we will evaluate the ejection balance and coexist with other systems, such as interference with water transportation and recycling marks, date clock, etc.

Question IV:

The design of the water channel system is based on four requirements (the cooling line should be as balanced as possible. The water cooling line shall not interfere with other mechanisms. The water channel equipment shall meet the customer’s standards and be easy to install. Each water channel line shall be displayed with identification numbers or marks (in and out).

 Question V:

how to ensure the manufacturing accuracy of the mold and the accuracy of the molding products, this mainly depends on the manufacturing accuracy of the mold cavity, the insert, and the mold core size. The accuracy of the mold cavity number or the accuracy of the parting line will directly affect the size of the product. Firstly, we need to make the manufacturing process plan and flow chart. Each completed manufacturing process must be fully inspected and the data inspection list must be recorded in the datasheet. After the manufacturing is completed, the workpiece shall be processed and maintained.

The design of the parting line of plastic mold is also an important part. If the design is not reasonable, the part is not easy to demoulding or even damage the mold. Here are the design principles for the parting line of mold

It is convenient to eject out the plastic part and simplify the structure of the plastic mold. After the demoulding direction is selected, the position of the parting line should make the plastic part fall done without any interference, like sliders, etc.

For the plastic part with high coaxiality accuracy, the parting line should be selected at the position where two diameters can be placed on the lower mold or upper mold at the same time.

When the precision of the plastic part along the height direction is required to be high, the half overflow cavity should be used. If the transverse flash is formed at the parting line, it is easy to ensure the height precision, while the non-overflow cavity is not easy to ensure.

When the radial dimension accuracy is high, the influence of flash thickness on the accuracy of the plastic part should be considered, as shown in the figure. If the vertical parting of plastic parts is easy to ensure, the horizontal profile is difficult to control due to the thickness of the flash, which affects the accuracy of plastic parts.

Ensure the appearance of the plastic part, it shall be easy to clean the flash and not easy to damage the appearance. The flash produced by the parting surface as shown in the figure shall be easy to clean and not easy to damage the appearance of the plastic part.

It is convenient for the manufacture of plastic mold and the processing of forming parts. The improved parting surface makes the processing concentricity of plastic mold low, easy to manufacture and the flash does not damage the appearance of plastic parts.

Ensure the strength of the formed parts, for example, when determining the parting surface, avoid the thin wall and sharp corner of the formed parts.

In addition to the design elements of general molds, the following points should also be considered in the design of precision injection molds:

  •  Adopt proper mold dimension tolerance;
  •  Prevent forming shrinkage error;
  •  Prevent deformation of injection part;
  •  Prevent the deformation of demoulding;
  •  The manufacturing error of the die/mold is minimized;
  •  Prevent the error of mould precision;
  •  Maintain mold accuracy.

Prevent the error of mold precision; classification of processing molds in plastic mold factory and requirements of various points for attention

There are many kinds of plastic injection molds, which can be roughly divided into ten categories. According to different requirements of a part material, physical and chemical properties, mechanical strength, dimensional accuracy, surface finish, service life, economy, etc, different types of injection mold are selected.

The plastic mould with high precision needs to be processed by a high precision CNC machine, and the material and molding process of the mould have strict requirements. Mould technology is also needed to design and analyze.

Some of the parts have special requirements during molding, so advanced technologies such as hot runner, gas-assisted injection molding, nitrogen cylinder, etc. are needed for plastic mold.

Plastic mold manufacturers shall have CNC machine tools, EDM machine tools, wire cutting machine tools, and CNC profiling milling equipment, high-precision grinder, high-precision three coordinate measuring instruments, computer design, and related software, etc.

In general, large metal stamping dies (such as automobile cover part die) should consider whether the machine tool has a blank holder mechanism, even edge lubricant, multi-position progressive, etc. In addition to the punching tonnage, the punching times, feeding device, machine tool and die protection device should be considered.

The plastic mold manufacturing capacity and process of the above are not possessed and mastered by every enterprise. When choosing a cooperative plastic mold manufacturer, we must know its processing ability, not only look at the hardware equipment, but also combine the management level, manufacturing experience, and technical force.

For the same set of mould, there is sometimes a big gap in the quotation of different mould manufacturers. You should not pay more than the value of the mold, but also should not be less than the cost of the mold. Plastic mold manufacturers, like you, want to make a reasonable profit in business, ordering a set of molds with a much lower price will be the beginning of trouble. You should start with your own requirements and measure them comprehensively.

If you have any requirement for precision mold manufacturing services, you are welcome to contact, Sincere Tech is a professional custom precision plastic injection molding and molding company in China, We offer precision injection mold/molding for the medical industry, electronic industry, automotive industry, and so on.

Plastic molding technology

Plastic molding technologyPlastic molding technology continues evolving with the market and with the advances in science. Plastic molding is the process used in producing plastic components for a variety of industries.

When plastic resin materials are heated the resin will flow, and can then be injected into a mold. A plastic mold consists of two halves referred to as the “A” side (cavity side) and the “B” side (core side). The “A” side is where the molten plastic enters the mold, and the “B” side contains the ejector system which removes the parts from the mold.

Plastic Molding Includes Many Terms and Components

Plastic molds are required to have many components in order to make high-quality plastic parts. Below is some of the terminology used to describe the components and processes that are required when producing injection molded parts:

  • Sprue – this connects the nozzle of the injection molding machine to the main runner, or cavity
  • Runner – this component conveys the melted plastic from the sprue to the gate and into the part
  • Gates – these are the openings that allow the molten plastic to be injected into the cavities of the mold
  • Cold Runner mold – this design involves the plastic entering into the “sprue” and then traveling through the “runner” where it then enters the part cavities through the various “gates.”
  • Hot Runner mold – this design is an assembly of heated components used to inject molten pPlastic moldslastic into the cavities of the mold. Hot Runner mold usually makes mold more expensive to manufacture but allow savings by reducing plastic waste and reducing the cycle time.

When observing plastic molding products, you will often see a line running between different sides of the finished plastic part. Here are some descriptions of why parts have a specific appearance:

  • The Parting Line – this occurs anywhere there are any two pieces of mold that meet.

There are also several configurations of plastic molds. These configurations are described as

follows:

  • The Two Plate Mold – consists of one parting line where the mold splits into two halves.  The sprue, runners, gates, and cavities are all on the same side of the mold.
  • The Three Plate Mold – has a runner plate in between a moving half and a fixed half.  These molds will have two parting lines and are used because of their flexibility in gating locations.
  • An Unscrewing Mold – is what is used when there is a requirement for male or female threads on a plastic component
  • The Action Mold – these consist of a mechanical cam action incorporated in their design, when a hole, slot, undercut or thread is needed that is not perpendicular to the parting line.
  • The MUD Unit Mold– these are standard frameworks for toolsets (u-frame), which allow for custom-machined tooling inserts to be made for specific components.

Large Plastic Molding Runs Cost Less 

Plastic injection molding offers many industries a huge number of benefits.  In large runs, molding is much cheaper than when machining the parts individually. The over-all manufacturing speed is much faster with this approach as well. This is one of the many reasons there are so many different types of injection molding processes. Some of these include:

Cold runner mold

Insert Molding – This is the process of putting a metal insert into a mold and then molding plastic around the insert.  Since multiple parts are manufactured together – this eliminates the need for a secondary assembly operation.

OverMolding – This is the process of over-molding, and the production of injection molded parts that seamlessly combines a rigid plastic with a rubber-like elastomer.

Family Molding – This is a process that utilizes a mold that contains various shapes of cavities to mold all the plastic components for one completed part.  Family molds are used when the different plastic components are made from the same material.

Injection Molding CleanRoom – This is the process used primarily for medical components. It is the injection molding process that is performed in a cleanroom environment in order to protect the parts from any contaminants.

When considering having plastic parts custom designed and molded – SINCERE TECH is the ideal partner for your plastic component or device.

SINCERE TECH is your single-source solution for your device by providing mold building, design, and engineering, injection molding as well as injection molding cleanroom and any secondary operations that may be required to complete your project. contact us now to know more information