Insert and Overmolding Services

Insert molding is a plastic injection molding process whereby plastic is injected into a cavity and around an insert piece or pieces placed into the same cavity just prior to molding, thus the term insert molding. The result of insert molding is a single piece with the insert or inserts encapsulated by the plastic.

The insert(s) can be made of metal or another plastic. Insert molding was initially developed to place threaded inserts in molded parts and to encapsulate the wire-plug connection on electrical cords. Precision plastic insert molding is also used quite extensively in the manufacture of plastic medical devices and military molding.

Applications of insert plastic injection molding

Typical applications of insert molding include insert-molded needle hubs and luer fittings and bifurcations, as well as encapsulated electrical components and threaded fasteners. There are few design limitations or restrictions on material combinations with our precision plastic injection molding.

Insert molding expands the capabilities of plastic and can help reduce the cost of products by limiting the amount of costly metals needed to manufacture products.

The plastic injection insert molding process can be a highly efficient alternative to the assembly of discrete parts using soldering, connectors, fasteners, or adhesives. Its benefits over such methods include:

• Reduced assembly and labor costs
  Because insert molding joins numerous components with thermoplastic, assembly and labor costs are greatly minimized. For example, a single stamping can be overmolded, then perforated to create multiple circuit paths.
• Reduced size and weight
  By eliminating fasteners and connectors, and by combining the physical strength of resin and metal inserts, insert molding yields smaller and lighter components.
• Increased reliability
  With every part tightly secured in thermoplastic, an insert molded component prevents part loosening, misalignment, improper terminations, and other problems. The thermoplastic resin also provides improved resistance to shock and vibration.
• Increased design flexibility
  Designers appreciate the virtually unlimited configurations that the precision plastic injection molding process allows. For example, in creating a 3D circuit board, overmolding permits circuitry to move freely through the part, from inside to outside, up walls, down in holes-and the plastic ties it all together.

Overmolding Services

Overmolding is the precision plastic injection molding process where one material is molded over a second material. The materials do not have to be the same but they must be compatible. For instance, you should not plan on injection molding the second material onto the first material if they are not compatible for the specific application. One should not deform the other where it matters. If the proper materials have been chosen, overmolding the part will form a strong bond that is maintained in the end-use environment.

Plastic Molded Concepts has many years of experience in overmolding (or insert molding) connectors, large inserts, as well as small inserts. One particular overmolding was to overmold a printed circuit board with flexible PVC whereby the finished product had a male and female connector at opposite ends for a completely finished product ready to use in the electronic field application.

Two color molding	Aluminum Core	Threaded brass inserts molded into the housing
Bottom view of the plated copper inserted part	Top view of the plated copper inserted part	Stainless insert/bearing surface for this fan
Thin Copper plates molded into the part. Small part 3/4"	Stainless shaft/bearing molded into part	Two color molding

If you are interested in the benefits of overmolding and precision insert molding, contact us for a quote today. Our precision plastic injection molding services can help reduce the cost of fasteners and adhesives as well as create strong reliable parts.