Professional Insert Molding Services

Insert molding involves placing pre-formed inserts (typically metal) into a mold before injecting plastic around them in a single shot. Overmolding is a multi-step process where one material is molded over another plastic substrate. Insert molding is ideal for incorporating metal components, while overmolding is better for creating multi-material plastic parts with different textures or properties.

Common inserts include threaded fasteners (brass, steel, stainless steel), bushings, electrical contacts, magnets, springs, and various metal components. The insert material should be compatible with the molding temperature and provide good adhesion with the plastic. We can also accommodate ceramic, glass, and certain plastic inserts depending on the application requirements.

We ensure strong insert retention through proper insert design (knurling, grooves, or threads), optimal mold design, precise temperature control, and appropriate plastic flow patterns. We also perform pull-out testing to validate bond strength and can apply surface treatments to inserts when necessary to improve adhesion.

Lead times typically range from 15-45 business days from mold design to sample delivery, depending on part complexity, mold requirements, and insert specifications. Prototype molds can be produced faster (10-15 days), while production molds may take longer. We provide detailed project timelines during the quoting process.

We typically achieve general tolerances of ±0.025mm (±0.001″) for insert molded parts. Tighter tolerances are possible for critical features, depending on the part geometry, material selection, and insert design. Insert positioning can be controlled to within ±0.05mm (±0.002″) with proper mold design and process control.

Yes, we support projects from prototype quantities (10-100 parts) to high-volume production (millions of parts annually). We offer different tooling solutions based on volume requirements: aluminum molds for prototypes and low-volume production, and steel molds for high-volume production runs.

Key design considerations include: proper insert sizing relative to the plastic part, adequate wall thickness around inserts (minimum 0.5mm), appropriate draft angles for demolding, avoiding sharp corners, ensuring thermal expansion compatibility between materials, and positioning inserts away from gate locations to prevent displacement during injection.

Yes, we provide comprehensive Design for Manufacturing (DFM) analysis at no additional cost. Our experienced engineers review your design for manufacturability, suggest optimizations for cost and quality, assist with material selection, and recommend insert specifications. We also provide mold flow analysis when necessary to optimize the design.