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Insert Mold: Combine Multiple Materials, Eliminate Assembly Steps, Metal Threaded Inserts, Single Piece Assembly


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Insert Mold

When a specific design requires combining multiple materials into one finished part, the cost-effective process known as insert molding may be the solution you need.

BMJ's engineers can help design the molds, as well as the insert to be integrated into the finished product to ensure proper fit and part performance.

  • With Insert molding, a plastic part is formed or molded directly over or around metal or plastic components, resulting in a single piece assembly

    A typical example is a plastic handle molded over a metal screwdriver shaft
     

  • This value-added molding operation eliminates need for costly additional assembly process
     
  • The process was originally developed to place threaded inserts in molded parts, and to form the plug around the prongs on the ends of electrical cords
     
  • It was found that molding directly over metal part saves time and money by eliminating an assembly step

Today, there are few design limitations or restrictions on material combinations.
 

Insert Molds: Design Considerations

Insert molding has become a common method for manufacturing mixed material parts. The basic design rules for insert molding are generally similar to those for standard injection-molded parts.

There are, however, a few design elements particular to insert molding that should be considered, that may affect the part's design:

  • Insert material used
     
  • Pull and compression-strength requirements of the insert
     
  • Leak resistance requirements of the finished part
     
  • Axial forces, or torque, the insert will be subjected
     
  • Voltage requirements for electrical applications
     
  • Design of insert - i.e., sufficient "anchors" incorporated into the insert's structure to properly secure it into the plastic part
     

Each of these areas must be addressed before our engineers can select the proper plastic material, and build the mold to perform optimally with the materials.
 

For a quote or more information about how we can help your project, call 765-457-1166, or send us an email, or submit this short form:

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BMJ built individual injection molds to produce the five separate plastic parts for this SUV power distribution box assembly
BMJ built individual injection molds to produce five plastic parts for this power distribution box.

More Injection Molded Parts

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and many more!

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