Make Strong, Functional Prototypes and Production Parts
Insert Molding Service
Custom insert molding services for high-quality prototypes and on-demandparts. Get a free quote with competitive pricing and short lead times.
Strong And Sturdy
Specializing In Insert Molding Services
We are a factory business that provides engineering, custom injection molding and contract manufacturing services. Our customers bring demanding applications that require insert molding services, and our professional engineers provide a complete service. All of our injection molding machines are capable of high-speed automation and production insert molding services. Our engineers have expertise and experience in areas such as medical mold design and manufacturing, high-volume automation for consumer packaging, and engineering grade resins and ultra polymers in electronics.
Expert Solutions for Your Insert Molding Needs
Do you have a project that needs customization? With insert molding, you can get the perfect component for your concept manufacturing needs. Xtmade offers custom insert molding to help you turn your final product into reality. Our experts will work with you to provide high-quality results in a short period of time.
During this process, we will use a robotic arm to insert the metal part into the mold cavity to achieve a specific shape. Then, we allow plastic to enter the mold, cover the metal part and form the desired shape.
The main purpose of insert molding is to combine the desired characteristics of metal and plastic into one product. Common applications for insert molding include wires, insulated pipes, and tools such as screwdrivers. Manufacturers often use insert molding to protect metal parts with a durable plastic layer.
Range of Mould Making Options
Our certified injection mould making shop allows us to quickly transform your 3D part data into high quality injection moulds at top speed. We offer design and manufacturing services from tooling and moulds to prototyping and production runs. Plastic blow moulds, aluminium and steel moulds, 2- and 3-shot moulding are also available. With Xtmade you own your tooling, so our factory can also provide mould maintenance services.
Design Guidelines for Insert Molding Services
Our insert molding services enable you to manufacture parts that meet various functional requirements. We ensure the quality of your insert molding projects through the following molding design needs that are executed in a specific manner.
Machining
We have large capacity vertical machines that are designed to perform plastic molding processes through insert molding and have a set of design guidelines that are accurately followed by our experienced and expert engineering team. The machines we use for insert molding have very tight tolerances, which ensures that the information of the plastic part is accurate in plastic injection molding. We know that even a tiny misalignment of the millimeter level will eventually lead to product failure, which is why we ensure that there is no margin of error.
Inserts
There are many different types of inserts used in the design and manufacturing of molded parts. These metal inserts in insert molding are usually made of brass, stainless steel, or regular steel. The mold is placed vertically in the machine manually or automatically through CNC machining. The vertical position is to ensure that the mold remains safely in place with the help of gravity during the insert molding process. The molten plastic is now poured into the mold and the mold is closed.
Threading Options
The threading options allow manufacturers to put pipes, screws, or anything else in the specified position of the mold. Their purpose is to ensure that the mold does not dig into the product. Since the product needs to be connected to external conduits in a variety of ways, the mold will allow the final product to remain functional and useful.
Insert Molding Pioneers
We have years of experience in handling the complexities of insert molding and providing turnkey solutions to our customers. As with all molding, early involvement in the design process can result in significant savings in tooling costs and part prices. Contact us today for a quote
Materials used for insert molding
Here are the most commonly used materials for Insert injection molding:
- ABS
- ABS/PC
- Acetal
- Delrin
- ETPU
- HDPE
- LCP
- Nylon
- PBT
- PC/PBT
- PEEK
- PEI
- PET
- PETG
- PMMA
- PPA
- PPE/PS
- PS
- PSU
- TPU
- LDPE
- Polycarbonate
- Polypropylene
Insert material
Insert molding is generally most commonly used for the embedding of screws or studs. Brass will not rust, has corrosion resistance, is cheap, and is easy to process. It is the most commonly used material in insert molding.
In addition, copper, aluminum, steel, hard heterogeneous plastic parts, ceramics, glass, plastics, etc. can all be used as insert materials. In product applications, we will design the shape and structure of plastic parts according to the thermal expansion coefficient of different materials.
Finishing Options
Molded parts can be finished in a variety of ways, either to cover a purely aesthetic surface or to provide some form of protection. The finish should beautify and enhance the refinement and functionality of any part. At Xtmade, our injection molded parts can be finished in any of the following ways:
- As-Made: Also known as “As Machined,” the part will be as molded, with tool marks still visible. This finish is suitable for parts that do not have any cosmetic emphasis or to hide industrial parts.
- Shot Blasting: Shot peening is used to level the surface of machined parts and create a uniform finished surface.
- Pad Printing: Pad printing is a decorative technique used to transfer ink markings, logos, or text from a pad printing station to a part.
- Etching: Etching is a method of engraving a pattern, mark, or text on the surface of a molded part.
- Textured Finish: Molded parts are leveled with fine stone dust before sandblasting to achieve a textured surface appearance. Suitable for parts that require a dull or satin finish.
- Laser Finishing: Etching, engraving or carving graphics, text, logos or markings on molded parts using a laser beam.
- Semi-gloss: Semi-gloss parts have a lower gloss and require sanding with fine sandpaper to achieve gloss.
- Glossy: Glossy finishes are used to achieve a mirror-like smooth finish in molded parts. Parts are sanded and polished with a diamond polishing wheel. These parts have the smoothest finish compared to other finishing options.
- Matte: Matte finishes are suitable for removing machining marks on molded parts without overly affecting the appearance. The mold is smoothed with the help of fine stone powder. Matte finishes are suitable for die casting or thermoset injection molding parts.
- Custom: Choose from a range of unique custom finishes or a combination of some standard finishes.
What is Insert Molding?
Insert molding is the process of molding or forming a plastic component around other non-plastic components or inserts. The inserted components are usually simple objects such as threads or rods, but in some cases, inserts can be as complex as batteries or motors.
In addition, insert molding combines metal and plastic or multiple materials and components into a single unit. The process utilizes engineered plastics for wear resistance, tensile strength, and weight reduction while utilizing metallic materials for strength and conductivity. The benefit is that parts can be mass-produced faster than if the entire part were machined from metal. While insert molding increases cycle time, it is still much faster than CNC machining a part from a solid block. Additionally, by insert molding metal where necessary and replacing the rest of the part with plastic will in turn reduce the overall weight of the part.
Insert Molding vs.Overmolding
Insert molding and overmolding are two different processes, each producing different products. The overmolding process involves molding one material over another. The base layer is molded first, and then additional plastic layers are molded over and around the original part. This creates a finished product. Overmolding produces a durable, long-lasting, and safer finished product.
In contrast, insert molding involves injecting the insert material into the mold cavity before injecting the plastic into the mold. The final product is a single piece with the insert encapsulated by the plastic. Plastic injection molded inserts offer a fast and cost-effective assembly process that produces smaller, lighter parts.
Insert Injection Molding Benefts
Insert Molding is an injection molding process that works especially well for parts that have threaded holes. lt can also help you create better wheels, pulleys fan blades, and other similar parts. Done correctly, insert molding can help:
- Eliminate assembly: You can make insert molded parts all at once instead of having to do assembly after the fact
- Reduce costs: insert molding costs more than standard injection molding,but the costs are usualy offset by the fact that you no longer need to do post assembly.
- Lower the size and weight of the part: A plastic part with a metal insert is generally lighter than an al-metal part.
- Improve reliability: Metal mold inserts wil guarantee the function of threads and mitigate wear and tear over the part’s life.
- lmprove part strength: Because it’s a “one-shot” process, it can produce stronger pats than overmolding and other processes.
Industries We Serve
Automotive
Medical
Aerospace
Consumer products
New Energy
Industrial machinery
Ready to start your next insert molding project?
We’re ready to help you with your project. Contact us today and let’s get started.
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