Insert Molding Service | Custom Plastic & Metal Solutions

What is Insert Molding?

The insert molding is a special type of injection molding in which an insert of metal, a threaded insert, or other pre-shaped part is inserted into the mold, and the molten plastic is then injected around it, to form one part and one part only. This metallic-to-plastic bonding gives a component of higher structural integrity, enhanced durability, and minimum secondary assembly. This has been likened to heat staking or screwing, but insert molding is the winner because of:

• Higher bonding strength
• Improved cycle time performance.
• Better location accuracy.
• Reduced material waste
• Lower production cost

It is extensively common in electronics, in automotive, in medical equipment, in consumer goods, and even in aerospace-grade molded components.

The Ultimate Guide to High-Precision Plastic and Metal Insert Molding Solution

• The need to create a superior insert molding service has increased by leaps and bounds in the present-day manufacturing environment, where products are required to be light, strong, smarter, and reliable. The industries in the world are more inclined to use insert molding due to its fact that it provides an ideal combination of plastic and metal, high strength, the less amount of assembly steps, and high performance. No matter whether it is a small connector in an electronic gadget or a robust car part, insert molding is at the core of contemporary engineering.
• SunOn Mould, being one of the most innovative manufacturers of moulds in the world, has put a combination of technology, years of precision crafts, and complete integrated molding solutions to present world-class service of the insert molding. Be it the customers require custom insert molding, plastic insert molding, or metal insert service, SunOn engineers each minute detail, starting with the case of the mold flow analysis to the fabrication of the mold tooling.

Why SunOn Mould is Top of the Global Insert Molding Industry?

SunOn is a company that is ISO certified and focuses on the complex multi-material insert molding, like:

• Plastic insert molding
• Plastic insert molding of metals.
• Insert the service of high precision.
• Plastic part custom insert molding.
• High-volume and low-volume molding services.

SunOn has a world-class manufacturing plant, robotic insert loading systems, and automated molding systems, which means that each part, big or small, connector, industrial component, etc., is manufactured with the highest level of accuracy.

Insert Molding Works: Behind the Scenes of the Technical Process

The art of magic in the process of insert molding is the smooth flow of engineering design, mold constructions, insert positioning, and plastic injection. SunOn is a scientific molding strategy with the help of information, sophisticated simulation, and accurate mold production.

Mold Design - Insert Molding

The base starts with a well-optimized design of the cavity of the mold, taking into consideration:

• Parting line design
• Gate placement
• Tolerance management
• Shrinkage control
• Surface finish quality
• Insert alignment accuracy
• Material bonding strength

The engineering department of SunOn conducts a mold flow analysis to determine the behavior of resins, their shrinkage, pressure distribution, and cooling patterns, and so on, to guarantee perfect outcomes.

Insert Placement Accuracy

Metal inserts- threaded brass inserts, stamped inserts, wire terminals, or pre-formed metal parts are fitted in the mold with:

• Robotic loading systems are used to insert objects.
• Internal fixtures that are precise.
• Anti-shift locking features

This guarantees zero displacement in injection.

Injection Molding Process of Plastic

After attaching inserts, injection of molten thermoplastic resins such as ABS, nylon, PC, TPU, or reinforced resin materials around the inserts is done. In contrast to overmolding, insert molding envelops the plastic directly around the insert placed and not around a second layer.

Multi-Extrusion and Multi-Injection

With its modernized plant, SunOn is capable of making:

• Multi-material molding
• Two-shot injection molding
• Multi-shot molding

The processes are ideal for molding electronic components, automotive insert molding solutions, and medical device insert molding.

Cooling, Ejection, and Quality Control

After cooling, the ejection of the molded part is checked with:

• CMM measurement
• Structural strength tests
• Check integrity: Bond integrity detection.
• Checks of tolerance and dimensional checks.

SunOn adheres to high standards of quality assurance in injection molding, whereby all parts are of international standards.

Uses of Inserts Molding: Industrial High-Value Uses

Molded parts are also popular in industries as they are dependable, durable in structure, and efficient in design.

Electronics Industry

• Connectors
• Switch housings
• Embedded terminals
• Sensor casings
• Wire terminal molding

Electronic producers choose injection molding as it enhances durability and minimizes wiring defects.

Automotive Industry

It is the insert molding service of SunOn that is trusted with:

• Automobile insert molding systems.
• Engine bay components
• Control modules
• OEM bespoke inserts.

All these sections have to resist heat, vibration, and wear over time, and in this respect, SunOn has led the way with thermoplastic solutions of moulding solutions.

Medical Devices

Insert molding is ideal for:

• Surgical handles
• IV components
• Observing the housing of the monitoring equipment.
• Parts of high-precision fluid control.

The medical parts need cleanroom molding, high accuracy, and biocompatible resins.

Aerospace and Industrial Applications

Molded components are inserted in:

• Molded components of aerospace-grade.
• Manufacturing of industrial insert molding.
• Rugged housings and connectors.

Such industries require lightweight components, accuracy, and reliability, which are the specialty of SunOn.

How to Select Material to Use in Perfect Insert Molding?

The materials that SunOn chooses are determined by:

• Heat resistance
• Electrical insulation
• Mechanical strength
• Bonding compatibility

Insert Molding Tooling: Accuracy in Fabricating to the Nth Degree

One of the strengths of the manufacturing by SunOn is its expertise in manufacturing precision molds. High-quality molds ensure:

• Increased consistency of products.
• Optimization of the faster cycle time.
• Reduced insert shift
• Increased quality of surface finish.

The tooling at SunOn is constructed with:

• CNC machining
• EDM cutting
• Wire cutting
• Polishing & texturing
• Hardness treatment
• Mold tooling fabrication

Each of the molds is tailor-made and designed to be most efficient and durable.

Cost-Benefit: Why the Insert Molding Saves Money

An effective insert service will minimize:

• Product weight
• Assembly steps
• Labor cost
• Material consumption
• Risk of assembly errors

Why SunOn Mould Will Be the Best Manufacturer of Insert Moulding?

This is the reason why major brands worldwide consider SunOn as their choice of insert molding manufacturer:

• Wholly automated insert molding machines.
• Accurate loading of the robotic insert.
• Tight tolerance management
• Deep technical engineering
• Molding experience- Multi-materials, 2K.
• Molding services are also ISO-certified.
• Rapid insert molding of prototypes.
• Mass production in bulk molding.
• Lead time optimization

Conclusion

Insert molding is not just a manufacturing method; it is an exquisite blend of accuracy, design, and engineering art. Insert molding is at the heart of the current manufacturing innovation, due to its capacity to fuse metal and plastic into one, solid, and working part. SunOn Mould is the pioneer of this change with unsurpassed custom insert molding, plastic insert molding, metal-to-plastic insert molding service, 2K injection molding, and high-volume production molding.