When fully metallic parts would weigh down an assembly, but fully plastic components don’t provide enough strength and durability, there is an option that combines the best of both.
Insert molding services take a preformed component, commonly a metal thread, pin, or bushing, and combine it with a molded plastic to create an integrated part. These services come filled with benefits that extend beyond just manufacturing, but trickle into post mold assembly operations and into component applications.
Agape Plastics highlights specific benefits of insert molding services and common real-world applications of this manufacturing method.
How Insert Molding Services Work
Insert injection molding involves placing the insert piece inside the injection mold where melted plastic material will be injected into. Once injected, the plastic begins to cool and solidify before the component is removed.
The insert stays in place whereas functional surfaces like threads or electrical contacts remain exposed. This allows for the core of the insert molded component to remain secure while allowing for other assembly operations to take place if needed.
Key Benefits
Insert molding services come with their own set of unique process and product benefits for customers and manufacturers alike. To start, insert molding allows for faster assembly time with a reduction in labor. Since components feature the metal aspect, if there is further assembly one step of the process has already been completed.
Insert molding lends itself to stronger fastening points in components. Metal inserts reinforce areas that are required to carry loads. And rather than solely relying on plastic, when metal is incorporated, additional strength and durability are present.
Even with the addition of metal into a plastic component, insert molded parts are still lighter and smaller in comparison to fully metallic components. Designers can combine the structural or electrical functionalities of metal with a plastic body. When these features are integrated, space needed for connectors, hardware, and mating parts is reduced which leads to smaller overall parts.
Improved reliability is another benefit that’s a byproduct of insert molding services. Combining components into a singular molded assembly can reduce the number of joints or fasteners that could loosen or misalign. This is largely dependent upon insert geometry, material selection, and the process control over molding.
Design flexibility is a benefit for injection molding, and insert molding services are no different. Even with the metal insert, since there are different applications for different insert, design engineers have flexibility to create unique designs that both fit the application and are manufacturable.
Common Applications
| Application | Traditional Insert Molded Component | Main Purpose |
|---|---|---|
| Automotive | Sensor housings, electrical connectors, threaded mounting features | Combine electrical or fastening functions with molded housings |
| Electronics / telecommunications | Connector bodies, plugs, sockets, embedded contacts | Position conductive components within insulating plastic bodies |
| Medical devices | Needle hubs, surgical instrument components, sensor housings | Integrate metal working elements with compact molded structures |
| Industrial equipment | Housings with metal bushings, heavy-duty switches, tool handles | Provide reinforcement, wear-resistant interfaces, or integrated electrical functions |
| Consumer products / appliances | Knobs, appliance components, threaded attachment points | Combine functional inserts with molded product bodies |
Need Insert Molding Services Performed? Contact Agape Plastics Today
Agape Plastics is one of the premier custom injection molding manufacturers in the United States. Since 1973 in our Grand Rapids, Michigan, facility we’ve created the injection molded and performed the insert molding services that OEMs, supplier programs, and other customer sources.
Our insert injection molding operations run parallel to our standard injection molding operations. From complete program management and various engineering capabilities including metal-to-plastic conversion, to robust quality management systems, our team is equipped to handle your manufacturing needs.
Each of our production programs is backed by stringent quality management systems. We’ve been IATF 16949:2016 certified for years. In order to keep quality at the center point of every project, we have a dedicated program manager, customer quality engineer, launch support with samples, tuning, part print development, and 24-hour customer support for on-site maintenance. We also have in-mold sensoring to ensure process control is properly followed.
Considering insert molding services? Contact Agape Plastics today.