Insert molding is an injection molding technique with properties similar to overmolding. This technique is extensively used in various industries to create highly functional components. Engineers and product designers use the insert molding design guide to ensure the efficient combination of plastic parts and threaded metal inserts.
GD-HUB are exported all over the world and different industries with quality first. Our belief is to provide our customers with more and better high value-added products. Let's create a better future together.
This article explores the insert molding technique, examining the processes involved. We will then provide detailed design guidelines for insert molding to help you get the best results from the process. Let&#;s get straight to it.
Generally, insert molding involves using threaded inserts to reinforce the mechanical properties and functionality of plastic components. It provides an effective method of fastening these materials together instead of using repeated assembly. Here&#;s a look at how the insert molding process works.
The insert molding technique requires high-end molding machines for product manufacturing. These machines are usually vertical and designed explicitly for molding through insert injection molding. In addition, the machines come with a set of design guidelines for injection molding that the engineering team needs to follow.
It is imperative to set the machine to the desired specifications according to the part design.
The machinery used for insert molding has tight tolerance that ensures the accuracy of the manufactured parts. A small error in the injection molding tolerances can lead to such a product&#;s failure.
Various inserts are available for use in the design engineering of molded parts. The inserts used in plastic molding are often made of stainless steel, brass, or regular steel. These molds generally feature threaded surfaces for enhanced adhesion to the product.
The molds are positioned in the machine vertically, either through CNC machining or by hand. The automated insertion process involves using robot arms to insert the components into the mold. As a result, you can be sure of efficiency, consistency, and precision. In addition, automated machines are faster and can withstand higher temperature levels during molding.
On the other hand, insertion by hand is an excellent choice for low-volume production. This process ensures that a full-time operator is present to perform detailed part inspections. However, insertion by hand may affect repeatability and precision. Moreover, the high temperature of the molding process may be an issue for operators inserting by hand.
After insertion of the mold, the mold will maintain its position during the insert molding process with the help of gravity. At this point, the molten plastic can be injected into the mold and closed. The injection is done under high pressure to force the molten plastic resin to fill all mold parts. Consequently, it ensures that the plastic adheres entirely to the inserts.
Molding the plastic component is the next step once everything is ready. The molten plastic enters the cavity, covering the carefully positioned insert. It is essential to keep the temperature constant during the molding process to ensure uniform solidification.
Maintaining holding pressure will also help reduce the shrinking effect and ensure there is no backflow into the barrels. The molding cycle time depends on the nature of the materials and the size of the intended component.
It is crucial to have an in-depth understanding of the insert molding design guide. Here are some of the critical factors to consider in your product design:
The size and depth of parts should be considered when making an insert mold design. These parameters will determine how long the molding process will take. Some parts will require the design and production of new molds, increasing manufacturing time and costs. It would be best to use inserts with rounded knurling, as there should be no sharp corners.
The production volume of plastic molded parts determines whether the manufacturer will use automated or manual loading. Automatic loading is faster and more precise. However, it involves using highly advanced CNC machines, which may increase injection molding costs. Therefore, choosing the proper loading involves practicing a cost-benefit analysis and understanding the production requirements.
The product application is one of the most critical factors to consider when planning a design for insert molding. This process is compatible with a wide range of materials. However, it would be best to identify the ideal material for each application.
For cost-sensitive parts, it is essential to consider the project budget. The budget includes the cost of the inserts and the cost of contracting a manufacturing partner. Furthermore, another cost element to consider is the increase in the price of a molded part caused by adding inserts.
Here are a few design guidelines for insert molding to consider when using injection molding with metal inserts.
Sharp corners contribute to the components&#; stress, making them potential failure points in the process. They increase production costs for injection molding plastic parts as mold creation requires EDM machining. However, rounded corners aid the easy flow of material through molds. Rounded corners and smooth transitions reduce the stresses on the mold walls. At the same time, they lower the differences in shrinkage rates as the material cools.
Maintain uniform thickness when designing the corners. Ensure that the radius inside has not less than half of your wall thickness. The outer radius should also be the addition of the internal radius and the wall thickness.
Shrinkages occur when the molten plastic resin cools, causing the locking of the part onto the mold. The draft angle enables the easy removal of plastic parts once shrinkage occurs. Adding a low draft angle to parts often leads to cosmetic abnormalities on the parts, known as drag marks. These injection molding defects occur due to the sticking of the parts to the mold.
The CAD system can help you easily optimize your draft angles. However, it would be best to do this at the final stage of your design to avoid complexities. Generally, the standard mold texture standards include 1 to 2 degrees of the draft angle per side and 3 to 5 degrees of the draft angle per side for additional texture. Also, consider using 5 degrees or more of draft angle per side for heavier texture.
A standard rule of thumb to consider when designing inserts in insert molding is to ensure that they remain small in relation to the plastic components in which you want to embed them. As with the overmolding design guide, a minimum of 0.016 inches (0.4 mm) of the insert should extend into the mold cavity to avoid sink marks in the plastic part. Likewise, the molding beneath the insert should be at least one-sixth of the insert&#;s diameter.
A boss is a protruding feature on a molded part, strengthening the slots or holes designed in the part&#;s surface. Bosses are common in parts that require assembling, like a receptacle for a screw. Generally, the standard boss diameter to add should be 1.5 times the insert&#;s diameter. However, the post-mold inserts usually cold-pressed into the hole need a larger boss diameter to withstand greater stress.
Delayed cracking in the plastic surrounding metal inserts is one of the most common defects associated with insert molding. This defect usually occurs when designers fail to consider the molded-in hoop stress of the insert. The two portions of the component can separate easily when the injected resin shrinks and cools. Consequently, they may eventually become damaged. Therefore, it is advisable to use strong and more durable resins for better elongation and wear-resistance qualities.
Metal bonding is another crucial factor to consider in the insert molding design guide. Although over-molded components can benefit from chemical bonds between layers of several thermoplastic resins, metal inserts do not establish chemical bonds with over-molded plastic components. Thus, you must design the plastic and metal components such that they mechanically bond with one another.
Wall thickness influences major features like functionality, aesthetics, and manufacturing costs. Carefully considering the wall thickness will help avoid constant mold modifications and prevent costly delays. Overly thin walls may require excessive pressure or may lead to air trapping within the plastic. Likewise, overly thick walls will be more expensive because of the greater use of materials and longer machine cycles.
The standard wall thickness for most molded plastic parts ranges from 0.080 to 0.160 inches, depending on the material. However, it is essential to maintain a uniform wall thickness as uneven wall thickness results in dimensional control complications.
The insert molding process is compatible with several molding materials. Engineers and designers often decide on the most suitable materials based on the requirements of the intended final products.
Here are the most common materials:
These materials are eco-friendly because you can use them multiple times. They have excellent chemical resistance and are ideal for ensuring variance and sheen in the insert molding method. Here are the common types of thermoplastics:
Thermosets are almost similar to thermoplastics. However, these plastic polymers cannot be reused or recycled. Manufacturers hardly use thermosets as they are not very cost-effective or eco-friendly. Some of the commonly used thermosets are:
The elastomers are natural and synthetic polymers with close properties to rubber. Engineers use elastomers in various applications due to their excellent elasticity and recyclability. Their eco-friendly nature makes them primarily suitable for making several plastic automotive products and home appliances. Some of the commonly used types of elastomers are natural rubber and polyurethane:
Insert molding is commonly used to add threaded fasteners into parent materials. It is useful for making components like computer and terminal boards, instrument boxes, automobile items, communication equipment, electronic equipment, and aerospace products.
Manufacturers often use undercuts to lock the fastener to parent materials. Likewise, a helical groove pattern help add tensile and torsional resistance to products. It safeguards the products against &#;torque out&#; and &#;pull out&#; defects.
The threaded insert technology is popular and provides purpose-built implants for outstanding results. Generally, fasteners are made of brass, even though aluminum and stainless steel are suitable materials. These inserts can be ultrasonically inserted, molded (using insert molding), or forced with heat.
However, insert molding offers improved mechanical qualities, a faster manufacturing rate, and more accuracy. It is crucial that your choice of threaded fasteners and their installations can withstand the design&#;s loading requirements.
Conducting a thorough end-use test program is essential in insert molding. It helps to detect likely faults or complications in the prototype stage of your development. Your test program should include parameters similar to the range to which the product may be exposed. For example, you should use temperature and pressure cycling that reflects the product&#;s applications.
Insert molding is a popular and highly specialized technique suitable for various industrial applications such as electrical components, automobiles, kitchenware, housing furnishings, etc. It is ideal for different reasons, including:
Insert molding offers an unrestricted level of configurations to the designers&#; preference. The process often permits the incorporation of various shapes and patterns. For example, you can include features in plastic parts to make them sturdier than most conventional products.
In addition, this process allows an efficient and seamless transition from plastic to metal parts. Since thermoplastic can hold inserts tightly, it prevents loosening. Also, it prevents design faults such as improper terminations and misalignment, enhancing design flexibility and reliability.
Insert molding offers cost-effective manufacturing as a result of its single-shot-only nature. Also, its cost-effectiveness is due to its ability to prevent post-molding assembly and separate parts installation. Consequently, eliminating these processes limits the motion waste while optimizing production time. Insert molding offers an economical and fast molding technique with enhanced efficiency and vertical injection machines.
The technique is an environmentally-friendly production process. It uses only the necessary amount of plastic to create parts, thereby improving sustainability. In addition, the process supports recycling plastic materials, which helps reduce waste.
Manufacturers use less material in the insert molding, reducing waste and costs. Additionally, the method prevents the use of fasteners and connectors, making the molded components smaller in size and lightweight. This technique is an excellent option for improving the strength of parts as it incorporates the strength of metal inserts in plastic components.
Insert molding eliminates the complexities of integrating components to produce substantial parts without secondary procedures that could increase production costs. This technique is compatible with a more extensive range of material options and end-use applications.
Having discussed the essential insert molding design guide, the process can be pretty complicated. Therefore, you need a professional and reliable injection molding partner like RapidDirect. We offer an extensive array of insert molding services to ensure that your parts meet all requirements without exceeding production timelines.
Try RapidDirect Now!
RapidDirect can review your design and provide a design for manufacturability analysis and report. Just upload your design files to our online quoting platform for fast and reliable feedback. Our dedicated engineering team, strong insert molding capabilities, and strict quality inspection standards ensure that you get the best results. Contact us now, and let us handle your next project.
Molding is the process of shaping or forming raw plastic into the form or shape that will be used for the finished product. Each product calls for a unique molding method. The overmolding process and insert molding design types are generally acknowledged as the most successful molding techniques now available on the market.
Molding is the process of shaping or forming raw plastic into the form or shape that will be used for the finished product. It is extensively employed in manufacturing various products, including bottles, automobile components, and medical apparatus.
There are many different kinds of molding, such as injection molding, blow molding, and compression molding. Molding techniques are specific to each product; nevertheless, the over-molding process and insert molding design types are generally acknowledged as the most successful molding procedures available on the market.
The first stage in a typical plastic manufacturing process is to heat a resin to the required temperature. The resin is then mixed with the necessary additives and placed in molds. Extra material is removed after the plastic has cooled, and the finished product is ready for sale.
Want more information on insert and overmolding services? Feel free to contact us.
This article will explain insert molding design works and the advantages and best practices of insert molding solutions.
Design Insert Molding is gaining in popularity due to its advantages. Which include high precision, the ability to be manufactured, and the simplicity of its application.
Molding can take many forms, one of them is called &#;Design Insert Molding.&#; This form of molding dispenses with the need for standard production processes and makes it possible for designers to produce intricate designs rapidly.
There are many different advantages of selecting design insert molding; some of these advantages include the following:
Insert molding allows for incorporating characteristics that would otherwise be impossible or difficult to achieve while developing a product. For instance, it can add a textured grip to a handle or raised lettering to a consumer electronics device.
Insert molding can be faster than traditional methods like machining or assembly. The entire cycle time is shortened since the inserts are inserted in the mold before the molding begins.
Insert molding is typically less expensive than other manufacturing techniques. This is because secondary procedures such as machining and assembly have been eliminated.
Insert-molded goods are often more durable than those produced using conventional methods. Because the inserts are molded into the product, a stronger bond between the two sections is formed.
Insert molding can produce things with more dimensional precision than other technologies. Before the molding process begins, the inserts are precisely inserted into the mold to verify that they are in the correct location.
Insert molding is fewer components involved. Insert molding typically results in the production of goods that have fewer flaws. Insert molding can reduce the number of individual features required to produce a single component. The end product will be of higher quality if it contains fewer components.
When necessary, insert molding is capable of handling both polymers and metals. As a result, it is a cost-effective option for those who want to create a wide range of products made from various raw materials.
Insert molding is a procedure in which an already manufactured component is put into a mold before the molding process. Metals, polymers, and composites could all be used in their construction.
After the component has been installed, the necessary material is poured into the mold and left to cool. The finished product is a single piece that includes the insert.
Moreover, insert molding follows the same fundamental principles as plastic injection molding. Molten resins are injected into a plastic mold fitted to the item&#;s geometric parameters. Plastic resins are injected into the mold and allowed to harden. After that, the inserts are extracted/ejected from the mold.
The only difference is that the metal is injected into the molten resin before the mold is closed. The plastic completely envelops the items in this manner, leaving no fractures and preserving uniform wall thickness.
The inserted product can be as simple as a blade or tube or as complex as a metal insert for a complex machine. Insert molding was chosen because it avoids using screws to attach multiple plastic components to a product&#;s cover.
The product is completely contained within the covering, and the covering is mechanically and naturally bonded to the product. Insert molding has various advantages. It is possible to save time and money by minimizing secondary assembly activities.
It boosts the longevity and stability of the final outcome by creating a stronger bond between the insert and the surrounding material. Furthermore, concealing the insert might improve the finished product&#;s overall appearance.
Insert molding is a versatile manufacturing technique that may be used to create various products. It is used in multiple automotive, aerospace, and medicine industries.
Insert molding is the technique of molding two or more materials together to form a single product. Insert molding can be used to create a variety of products. Molding techniques such as compression, injection molding, and transfer molding are all viable options for achieving this result.
Insert molding is a common manufacturing technique utilized for making components with several functionalities or when attempting to increase the robustness of a component. When it comes to the design of a product, insert molding offers several benefits that should not be overlooked.
Here are the following insert mold advantages:
When it comes to insert molding, a few crucial considerations must be considered to guarantee that the end result fulfills one&#;s expectations. Here are some of the things that should take into consideration:
It is critical to consider both the mold size and the pieces that will be produced when planning to insert molding. The size of the mold will influence the size of the finished parts. The size of the components determines the amount of material used to make the mould.
The material of the insert must be compatible with the material of the mold. One must also consider the qualities of the insert material, as this can affect the final output.
Insert molding materials of various types can be used when developing insert molding. Common materials include:
This substance is commonly used for heat-resistant goods, such as polymers found in electronics. Furthermore, it is used in goods such as spectacles that are difficult or impossible to create using other molding materials.
Polypropylene is a thermoplastic resin commonly used in water- and liquid-resistant products. This material is also widely utilized to make strong and long-lasting items.
These are light, transparent polymers having a low melting point. They are acid and basic-resistant and are widely utilized in everyday mainstream products such as consumer goods and medical molding companies.
This thermoplastic polymer is chemically resistant and has good toughness, dielectric properties, and impermeability. HDPE, MDPE, and LDPE are the most prevalent thermoplastic polyethylenes on the market. They are considered lightweight thermoplastic materials.
Nylon is a chemically and abrasion-resistant material that is very strong. Because of its high melting point, it can be used in place of metal in some applications. For heavy-duty applications such as production and extraction, nylon injection molding is the material of choice.
The material is typically certified to IL 94V 0 and has good halogenated solvent chemical resistance. Highly specialized procedures are subject to certain constraints where they exist.
They become permanently hardened and have no melting point after processing. As a result, they are well-suited for high-performance applications. They have exceptional heat and chemical resistance, as well as exceptional adhesion.
When developing insert molding with draft, several factors must be considered. The location, size, and shape of the object to be molded must all be considered. Incorporating draft angles into a design makes a part easier to expel from a mold and improves its overall moldability.
The draft angle determines the space between the part&#;s mold and the casting surface. The draft angle is commonly measured in degrees from the vertical plane at the part&#;s ear point. If the ear point is below the surface of the casting, the draft angle is negative and refers to the side of the object that will be in contact with the mold.
The draft angle is positive if the ear point is placed above the surface of the casting. Additionally, it indicates the side of the part that will be facing away from the mold. The final dimension of the component will be determined by the drafting precision and tolerances.
Undercuts, common in molding, present regular design issues for inserts. Undercuts are defined as any recess in part. That prevents it from being pulled from the mold in a straight line.
On the other hand, more intricate undercuts are conceivable but can be costly to create. Undercuts are frequently eliminated by simply redesigning the component.
If this is not practicable, there are several techniques for producing inserts for undercut-molded parts. A mechanical locking device can secure inserts, such as a snap-fit or interference fit.
A second alternative is to use adhesive to attach the insert to the component. Combining this method with a mechanical mechanism is customary to prevent the implant from slipping free.
More detailed designs are required if the insert is to be detachable. One solution is to use a two-part mold with a core that can be pulled out of the cavity with the insert. This type of mold is more expensive and complicated to design and build.
When designing an insert molding, wall thickness is critical. The insert&#;s wall thickness determines the product&#;s strength and durability. The insert may fracture or crack if the wall thickness is insufficient. Extracting the insert from the mold may be difficult if the wall thickness is too thick.
Insert molding is molding a plastic component around a metal insert. The insert is placed in the mold before adding the remaining plastic material. Threaded fasteners, such as screws, are routinely incorporated into plastic components in this manner.
Insert mold flow design is a routine technique that must be followed precisely to increase the likelihood of success. Below is the insert moulding design guide.
The first stage in planning insert molding is to prepare the machinery used in the technique. To ensure that the finished product is faultless, each component&#;s machine tolerances and alignment must be checked.
The next step is to choose the inserts that will be used. Metal or plastic can be used in most situations. The two most common metals are brass and stainless steel. Almost anything will do for plastic. The molds are then put vertically into the machine to guarantee they stay in position once it starts up.
There are numerous thread possibilities for insert molding. The process of placing materials into a mold is referred to as threading. The goal is to ensure that the mold does not generate the product insert but rather stays functional and useable throughout downtimes.
When everything is in place, and the design is finished. It is time to put the machine to work and create the desired end product. The length of time it takes to complete a product is dictated by its size. Also, the nature of its components.
Material selection, tool design, and process control are variables in optimizing the insert molding design process. Manufacturers may avoid potential problems and boost their chances of success by ensuring that these critical variables are considered and by following the insert molding guidelines. The molding process might take many forms, but it always adheres to the same principles.
Seaskymedical applies innovative injection molding technology to all of its manufacturing difficulties to provide the medical business with the safest and most reliable equipment. The company, for more than a decade, has given low-risk, cost-effective solutions to the healthcare industry. Furthermore, it offers clients comprehensive and qualified assistance throughout all project phases.
If you are looking for a medical plastic manufacturer and supply chain with more than ten years of experience to meet the unique demands of the medical and healthcare industries, consider working with Seaskymedical. Contact Seaskymedical if you want high-quality medical supplies and equipment to protect patients&#; health and safety. Apart from medical device injection molding, Seaskymedical also provides custom plastic injection molding services for other industries, if you are interested in it, feel free to contact us.
Are you interested in learning more about CNC Machining For Aerospace Prototypes? Contact us today to secure an expert consultation!