How does insert injection molding differ from over molding?

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insert injection molding differ from over molding

In insert injection molding, a metal or other hard material is embedded in a plastic product. This process cuts back on assembly time and labor costs by allowing the product to be molded around the insert. It also provides greater strength and flexibility than a part that is completely composed of plastic.

Inserts can be added to products ranging from standard compression limiters to the metal shanks on tools such as drills. The inserts are typically small and can be molded to fit a specific area of the finished product, such as a handle or bracket. Adding an insert to a plastic component can increase the durability of the finish by providing more support for the load, or reduce the stress from hooping over time.

When designing a product to be molded with an insert, it is important to understand the benefits and limitations of this process. The typical injection moldability design guidelines apply (add draft, maintain consistent wall thickness, avoid undercuts) but there are some unique considerations that are important for insert injection moulding. Most notably, the inserts must be compatible with the injection material used.

How does insert injection molding differ from over molding?

If the insert is not compatible with the injection material, it can cause problems when the product is molded. The most common problem occurs when the resin shrinks or flows around the insert. This can result in the insert sticking out of the final product, or it can cause the molded part to fail to function correctly.

A secondary issue that can arise is when the insert is too deep within the final product. The insert should not extend too far past the edge of the molded plastic, or it may be difficult to access and remove. In these cases, the insert may need to be trimmed to reduce its depth in the finished product.

Another consideration is the temperature of the injection mold. When an insert is placed in a plastic injection mold, the mold must be heated to the appropriate temperature for the material. Injection molds that are too cold can deform the plastic and cause warping of the finished product.

To prevent this from happening, a cooling system can be used to keep the injection mold at the proper temperature for the plastic being injected. The cooling system can also be used to control the flow of plastic, reducing the likelihood of hot spots in the finished product.

Firstmold Manufacturing Limited has experienced phenomenal growth since its inception in 2011. What began as a pioneering rapid prototyping service has evolved into a multifaceted manufacturing powerhouse. Firstmold’s unwavering dedication to excellence has enabled the company to expand its operations to include mold making, injection molding, CNC machining, die-casting, and product assembly, setting new benchmarks in the industry.

As with any manufacturing process, the cost of insert injection molding depends on the type and quantity of the metal or other hard materials being inserted into the plastic. For example, a metal screw is significantly more expensive to produce than a simple plastic screw. However, for products that require metal components to support or fasten other parts of the product, insert injection molding is an excellent choice. This process can significantly cut down on assembly time and labor expenses by eliminating post-molding assembly. Adding metal inserts to plastic can help strengthen the part, make it more durable, and even reduce its weight.

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