Insert molding is a specialized plastic injection molding process where pre-formed components, often made of metal or other materials, are placed into a mold, and then molten plastic is injected around them to create a single, integrated part. This method enhances the structural integrity and functionality of the final product by combining the durability of inserts with the versatility of molded 

Thingyfy uses advanced, high-quality molding machines designed specifically for the insert molding process. The insert molding process requires extremely tight tolerances to ensure that the manufactured plastic parts are properly molded. Even a slight misalignment of a fraction of a millimeter can lead to eventual failure of the molding process. Our state-of-the-art insert molding equipment can meet your most stringent specifications.

Insert Molding 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 open the door to exciting new products and processes. We welcome these advancements as we strive to provide our customers with the most advanced insert molding options. The insert molding materials we offer can be used with most thermoplastics.

Advantages of Insert Molding:

Enhanced Structural Integrity: By combining materials, insert molding produces parts with superior strength and durability.

Cost Efficiency: Despite the initial setup costs, insert molding can be cost-effective in the long run. The reduction in assembly time, combined with the high quality and durability of the parts, leads to significant cost savings.

Applications and Uses of Plastic Injection Inserts:

1. Automotive Industry:

• Connectors and Terminals: Insert molding is commonly used to produce automotive electrical connectors and terminals, where metal inserts (such as brass or copper) are encased in plastic for electrical conductivity and corrosion resistance.

  
  

• Control Panels and Switches: Insert molded parts can be found in automotive control panels and switches, where metal inserts (like bushings or threaded inserts) are encapsulated in plastic to ensure the functionality and strength of the assembly.

  
  

2. Consumer Electronics:

• Connectors: Insert molding is often used for producing connectors in electronics such as USB, HDMI, and power connectors, where a metal insert is molded with plastic to improve mechanical strength and electrical conductivity.

  
  

• Switches and Buttons: Buttons and switches that require durability and tactile feel, such as on remote controls, computer keyboards, or household appliances, often use insert molding to integrate metal parts like springs or contact points into the plastic part.

  
  

3. Medical Devices:

• Surgical Instruments: Insert molding is used to create parts like handles, housings, and tips for surgical instruments, where the metal insert provides strength and precision while the plastic provides a comfortable grip or ergonomic design.

  
  

• Implantable Devices: For medical implants like orthopedic components, insert molding can be used to combine biocompatible metals with plastic materials that are lightweight and capable of supporting medical procedures.

  
  

4. Aerospace Industry:

• Structural Components: Insert molding can be used to create lightweight and strong parts for aircraft, including interior components, panel housings, and connectors. The combination of plastic and metal in the molding process allows for high-strength components that are also resistant to vibration and stress.

  
  

• Fasteners and Mounts: Insert molding produces parts like fasteners, mounts, and brackets that are critical for structural integrity in aerospace applications. The metal insert ensures strength, while the plastic provides weight reduction and corrosion resistance.

  
  

5. Industrial Applications:

• Bearings and Bushings: Insert molding is ideal for creating bearings and bushings where a metal insert provides the necessary load-bearing capability while the plastic provides smooth operation and wear resistance.

  
  

• Tool Handles and Grips: Many hand tools, such as wrenches, screwdrivers, and pliers, use insert molding to combine a metal insert (for strength) with a plastic or rubberized outer layer (for grip and comfort). 

Insert molding and overmolding are two distinct manufacturing processes that result in unique product designs. Overmolding involves molding a second material over an existing base material. In this process, the base material is molded first, and then a second plastic layer is applied over it, creating a single, unified finished product. This technique results in a durable product with extended lifespan and improved safety features.

On the other hand, insert injection molding refers to the process where pre-formed inserts are placed into the mold cavity before the plastic injection molding process begins. During molding, the plastic material is injected around the insert, encapsulating it within the final product. This method offers a fast, cost-efficient solution that allows for the production of smaller, lighter parts with integrated components.

Thingyfy's skilled team specializes in the insert injection molding process, with the expertise to transform insert materials into high-quality plastic injection inserts. However, before proceeding with the insert molding process, several key factors must be taken into account. These include the overall cost, such as the expense of inserts and tooling. It is also crucial to ensure that the inserts can withstand the pressures and temperatures involved in injection molding, as extreme conditions may cause damage.

Other important considerations include:

• The method used to secure the insert during molding to ensure proper placement.

• The inclusion of bosses or undercuts that provide added retention strength within the molded part.

• A clear understanding of how various components and technologies will be integrated into a single product during the insert molding process.