What is inert molding
Insert molding is a manufacturing process that involves molding a pre-formed part, also known as an insert, into plastic resin to create a finished single product. The insert can be made of various materials, including metals, ceramics, or other plastic materials, and is placed into a mold cavity before the plastic resin is injected around it. if the inserts are made from plastic or a molded plastic parts, then we call this as overmolding, the first shot of plastic insert we named as substrate. if the inserts made with metal then we can see metal insert molding.
Insert molding is commonly used in industries such as automotive, electronics, and medical devices, where parts require high strength, durability, and precision. Insert molding can create complex parts with multiple materials or components in a single molding process, reducing the need for separate assembly processes and lowering production costs.
Additionally, insert molding can improve the quality and reliability of parts by creating a strong bond between the insert and the plastic resin.
When metals and plastics are inserted together in a molded part, or when multiple metals or materials are molded together into a single molding part, we call it metal insert molding or metal screw/brass insert molding. Sometimes, we also call insert molding as overmolding.
Custom Insert molding not only reduces assembly and labor costs but is also better than assembly parts as it 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 come from Chinese mold manufacturing companies, where low labor costs and high-quality control are significant factors. China can also do assembly for all of your ending parts together and ship them to you.
We are professionals in plastic mold making and plastic molding manufacturing for over 18 years, with a strong engineering, mold maker team, and quality control production.
We can make your project from start to end, no matter if it is normal molding, 2k injection molding, custom insert molding, medical plastic molding, metal insert molding, automobile industrial, cosmetic injection molding parts, home appliances injection molding, and many more.
The Process of insert injection molding ( moulding) and cost
Melted raw material is injected into a plastic mold using an injection molding machine, and the procedure for insert injection molding is the same as for regular injection molding. The press opens, allowing the ejector pins to release the molded pieces after cooling systems have solidified the plastic. The only difference is that before the mold closes, we need to put the metal inserts into the mold and start the molding process as normal injection molding, but we also need to do the mold fitting with the metal insert to avoid material leakage issues.
With the exception of the metal injected into the mold prior to the mold being closed, insert injection molding employs the same materials as injection molding. For example, the same injection molding machine, the same steel mold, the same structure mold, and the same thermoplastics are used. Although all of these injection molding machines are capable of working with thermoplastics, there may be instances in which a vertical injection molding machine must be used.
Certain injection molding producers employ vertical and horizontal injection molding presses, which rely on gravity to hold the insert in place while the mold closes. Cycle time is decreased because two bottom halves allow inserts to be inserted into one while the other is going through the molding process.
There are some of factors that effect to Insert injection molding costs.
The price of the inserts itself makes up the first element. The molding materials, including plastics like ABS, PC, or PA and metal inserts like steel or aluminum, can be used to create inserts. The material utilized, the size and intricacy of the insert, and the quantity needed will all affect the cost of the inserts. Making 100 pcs insert comparing to making 1000 metal inserts, unit price will be total different.
The cost of the insert mold is an additional factor in insert injection molding costs. The mold plays a crucial role in the injection molding process since it defines the finished part’s shape and characteristics. This initial cost will be more than unit cost, if you plan to make thousands of parts then making insert mold will be benefits. If the insert part made in plastics then we may called overmolding, this will need two molds, one for the first plastic parts and one for over molding, this will be increase the initial molds cost.
An further significant factor in insert injection molding costs is labor cost. Compared to standard injection molding, insert injection molding involves more labor since operators need to manually place the inserts into the mold before each shot. This will increase the cycling time and the manual cost,
To get an accurate estimate cost for insert injection molding, consult with a professional injection molding manufacturer will be better option. They can evaluate your specific project requirements and provide a detailed cost analysis based on 3D data and specifications, waste rate and production volume. This will help you make an informed decision and determine if insert injection molding is the right choice for your project, your are welcome to send us your insert injection molding project, we will quote you a price in 24 hours.
Below are some of the custom insert injection molding parts we made before. If you have any project that needs brass insert molding or any metal insert molding, send us your requirements for a quotation.
How insert molding can improve your molding parts and solve your issues:
An extremely effective substitute for conventional techniques of assembling insert pieces with adhesives, connections, welding, soldering, or fasteners is insert injection molding. There are numerous advantages to this cutting-edge method that can greatly improve the effectiveness and caliber of your molded components. Some advantages of insert molding over traditional injection molding are listed below.
Reducing Final Molding Parts
The smaller molding pieces produced by insert molding are among its main benefits. Compared to conventional assembly techniques, insert molding creates smaller pieces by molding metal inserts with plastics during the molding process. This shrinkage enhances the overall performance of the molding process in addition to saving material costs. Additionally, the parts’ weight is greatly decreased, which improves both performance and cost-effectiveness.
Decreased Labor and Assembly Expenses
Insert molding not only reduces size but also significantly lowers labor and assembly costs. In contrast to labor-intensive, multi-step traditional assembly methods, insert injection molding integrates two or more elements into a single molding part in a single shot. The labor and assembly costs are significantly decreased by this efficient method. Complex assembly procedures are not necessary because all that is required of a worker during the molding production process is to simply place the metal item into the mold. Moreover, a single shot is perfect for intricate insert molding parts since it may shape one insert or several inserts.
Enhanced Trustworthiness
The enhanced dependability that insert molding provides is yet another noteworthy benefit. Every component is tightly molded in thermoplastic during the insert molding process, guaranteeing a strong and long-lasting bond. By doing this, normal assembly process difficulties such part loosening, mismatch, misalignment, and others are avoided. The parts’ resistance to stress and vibration is further increased by the molding process’s use of plastic resin, adding to their dependability and durability.
Enhanced Flexibility in Design
Insert molding is easy for designers to think about how those part should be assembled together. Designers can save time and concentrate on other areas of the design by removing the need to think about how pieces will be assembled or how metal and plastic components will be attached together. With this insert molding process, there are lots of designs problem can be solved very easy.
Lower Injection Molding Expense and Enhanced Productivity
Insert molding helps to improve efficiency and lower overall injection molding costs. Operators may find it difficult to set inserts during the molding step, particularly if they are working with small or many metal pieces that are prone to falling. On the other hand, using vertical injection machines greatly increases productivity, saves time, and lowers the possibility of dropped or misplaced inserts. This helps to reduce the cost of injection molding while also improving the molding process’ overall efficiency.
Reduced Assembly and Labor Costs
Insert molding also offers substantial cost savings in terms of assembly and labor. Unlike traditional assembly methods that require multiple steps and labor-intensive processes, insert injection molding involves a single shot that combines two or more parts into an end molding part. This streamlined approach drastically reduces assembly and labor costs. During the molding production, a worker simply needs to insert the metal part into the mold, eliminating the need for complex assembly processes. Furthermore, a single shot can mold a single insert or multiple inserts, making it ideal for more complex insert molding parts. such as insert molding with 4-10 pcs of metal screws which we call screw insert molding.
Increased Reliability
Another significant advantage of insert molding is the increased reliability it offers. The plastic molding process tightly molds every part in thermoplastic, ensuring a secure and durable bond. This prevents issues such as part loosening, mismatch, misalignment, and other common problems associated with traditional assembly methods. The use of plastic resin in the molding process also enhances the parts’ resistance against shock and vibration, further improving their reliability and longevity.
Increased Design Flexibility
Insert molding also provides designers with increased flexibility in their design process. By eliminating the need to consider how parts will be assembled or how metal and plastic components will be fastened together, designers can save valuable time and focus on other aspects of the design. This increased design flexibility allows for more efficient and innovative designs, ultimately leading to better products.
Reduced Injection Molding Cost and Improved Efficiency
Furthermore, insert molding contributes to the overall reduction in injection molding costs and improved efficiency. The placement of inserts during the molding stage can be challenging for operators, especially when dealing with small or multiple metal parts that are prone to falling. However, the use of vertical injection machines significantly improves efficiency, saving time and reducing the risk of misplaced or dropped inserts. This not only enhances the overall efficiency of the molding process but also helps to lower injection molding costs.
Please get in touch with us if you need help with an insert mold project; we are your reliable source for any molding and insert mold requirements. With years of expertise in the field, we are experts at providing premium insert molding services that are tailored to each individual client’s needs.
Since every project is different, we at ST China Mold Company provide a variety of custom insert molding options to meet the specific requirements of each of our clients. To guarantee that we offer the highest quality insert mold and any other custom injection mold, we have skilled mold makers that operate with cutting edge machinery.
Our insert molding services are excellent and reasonably priced. In order to maintain cheap prices while producing high-quality insert molding goods, we employ cutting-edge technology. This enables us to offer low pricing to our clients without sacrificing quality.
At sincere tech China Mold, we specialize in offering custom injection molding and insert molding solutions for a variety of industries, including the packing, automotive, medical, aerospace, and electronics sectors.
We are dedicated to constant improvement and take pleasure in the caliber of our work. We’re constantly searching for fresh and creative approaches to enhance our procedures and offerings. To make sure we stay ahead of the curve, we make investments in the newest machinery and technology.
We have the knowledge and resources to meet your needs, whether they involve mass manufacturing of a single prototype or a larger order. Part design, mold construction, insert molding, and part assembly are among the services we offer. To make sure we give our clients specialized solutions that address their unique demands, we collaborate closely with them.
For a quote, kindly email us your 3D drawing and specifications. We will assist you with part design, mold creation, mass production, and component assembly in addition to providing you with the price within a day. Request a quote right now!
