Insert Molding Services
Elimold is an ISO 9001:2015-, 13485:2016-, 14001:2015-certified manufacturer of insert-molded parts and assemblies for demanding applications. Regardless of design complexity, we can turn around products that fit, form, and function as intended on time and within budget.
High Precision and Consistency Insert Molding
Our cutting-edge insert molding solutions use a unique combination of process optimization and robotic automation to produce parts with an extremely high level of consistency. Whereas the competition races to embrace insert-molding solutions, Elimold leads the industry, having replaced the operator handloading and removing of an insert with the loading and removing of those inserts by precision robotics. The introduction of and expertise in the use of this automation minimizes the variables that affect final part quality by ensuring a consistent, reliable, and repeatable process.
Elimold’s capacity demonstrates our core expertise in injection molding. From the simplest geometries and lightest-weight components to the most complex shapes and 20-pound parts, we have the experience to manufacture the parts you need. With a clamping force capacity of 40 to 2,200 tons, we will meet the force requirements of your project.
Insert Molding Solutions - High Production Efficiency
Insert molding is typically characterized by molding these components, referred to as “inserts” directly into a part.Insert molding is an injection molding process used to insert metal parts into plastic to create a final plastic component. There are 2 basic steps of this process: Firstly, getting ready the molding insert and loading it onto the mold before molding. Secondly, injecting the molten plastic into the cavity, cooling down, and taking out the final plastic component. Applications for insert molding are wide. Due to the inserts can be just about anything, from alloy threads to electrical contacts, the application possibilities are seemingly endless. It is important to understand the insert molding process, then design the part correctly to optimize the production process. Benefits include lower costs by eliminating handling the part a second time in the secondary department and a part that has greater function that plastic alone. Products that are candidates for metal replacement can still have performance strength utilizing insert molding at critical design features.
We Simplify the Manufacturing Process
We offer complete custom insert molding services from design to prototyping through production. All products and services are designed for manufacturability. The company is equipped for high-volume production with high-speed reel-to-reel capabilities, fully-automatic, high-cavitation production, and in-line automated welding and testing.
With insert molding, what is typically used to require a complex assembly can be produced in a single insert molded part saving our customers assembly time, labor and money.
We use a process called “reel-to-reel” or “Continuous Strip Molding”. This process takes reels of metal inserts and mold miniature plastic forms, in any configuration, that are blanked out and assembled to your product.
We offer full in-house automation design, implementation and maintenance.
The Elimold Way
Our build-to-print services are ideal if you have a thoroughly vetted design. With print, specifications, and a purchase order requirement in hand, we’ll take it from there.
If you have a project that still needs refinement, don’t worry. We’re here to assist you in achieving a simpler, more manufacturable design for your goals. Our build-to-spec services can turn your concept into finished products quickly and affordably. At our company, we believe in customization to meet your specific needs. We only create prototypes when necessary for testing and proof of concept. Our focus is always on tailoring your project to your unique requirements.
Comprehensive Manufacturing Services
When manufacturing components for critical applications, turning around quality products quickly is paramount. Elimold’s insert-molded part or assembly manufacturing services can help you achieve your production goals.
- Product Development
- Prototyping
- Tool and Die
- Precision Metal Stamping
- Machined Parts Process Conversion
- Insert Molding
- Reel-to-reel Molding
- Assembly
- Automation & Robotics
Insert Molding Services From Elimold
Insert molding is a key fabrication process across many industries and offers a wealth of benefits. Elimold is a full-service, custom injection molding provider that works with a variety of high-performance engineered thermoplastics. We operate the latest automation and molding equipment, which allows us to compete on an international scale.
Contact us today to learn more about our insert molding services, or request a quote to get started on your solution.
Insert Molding Design Guidelines
Our basic guidelines for insert molding include important design considerations to help improve part manufacturability, enhance cosmetic appearance, and reduce overall production time. View our design guidelines page for more in-depth details.
| US | Metric | |
| Maximum Part Size | 18.9 in. x 29.6 in. x 8 in. | 480mm x 751.8,, x 203.2mm |
| Volume | 59 cu. in. | 966,837 cu. mm |
| Depth | 4 in. form parting line | 101mm from parting line |
| up to 8 in. if the parting line can pass through middle of part | Up to 203.2mm if the parting line can pass through middle of part | |
| Projected Mold Area | 175 sq in. (plastic) | 112,903 sq. mm (plastic) |
| 48 sq. in. (silicone rubber) | 30,958 sq. mm (silicone rubber) |
Insert Molding Mold Fabrication
Each development project requiring insert molding services is managed by a project engineer who monitors and controls deliverables and provides regular status updates.
Elimold’s projects include insert molding services supported by MoldFlow analysis, viscosity profiles, cavity balance studies, pressure window characterization, gate seal time studies, and cooling time studies. Elimold engineers are well versed in insert configuration and design single-cavity R&D molds with steel insert areas. Interchangeable plates, inserts, and sub-inserts enable faster design iterations at a lower cost than creating a new mold for each functional change. SPI 103 and 104 grade molds are made of P20 steel and aluminum with hot and cold runners.
Production molds for insert molding service projects include high-cavity SPI 101 and 102 grade molds made of hardened steel. Cold, runner, hot gate, and hot runner molds are designed with up to 128 cavities.
Our mold maintenance plans for projects including insert molding services ensure that each mold is regularly cleaned and inspected at pre-defined intervals based on the number of setups and cycles. Mold inspections, general mold maintenance, major mold maintenance, and preventive maintenance are standard operating procedures.
Rich Choice Of Materials
Whether you’re a designer, engineer, or inventor, our materials will help you bring your ideas to life with precision and ease. Plus, our materials are affordable, so you can iterate and perfect your designs without breaking the bank.
Plastic Materials
Thermoplastics are considered environmentally friendly insert molding materials because they can be recycled multiple times. They are chemically resistant and ideal for ensuring differentiation and gloss during molding. The following are the main types of thermoplastic materials commonly used by Elimold:
ABS(Acrylonitrile Butadiene Styrene)
ABS+PC(ABS + Polycarbonate Alloy)
HDPE(High Density Polyethylene)
HIPS(High Impact Polyethylene)
LCP (Liquid Crystal Polymer)
Nylon 6(Polyamide 6)
Nylon 11(Polyamide 11)
Nylon 66(Polyamide 66)
PBT(Polybutylene Terepthalate)
PC(Polycarbonate)
PE(Polyethylene)
PEI(Polyetherimid)
PET (Polyethylene Terepthalate)
PMMA(Acrylic)
POM(Acetal)
PP(Polypropylene)
PPA (Polyphthalamide)
PPS(Polyphenylene Sulfide)
PS(Polystyrene Crystal)
SAN(Styrene Acrylonitrile)
LDPE(Low Density Polyethylene)
PVC(Polyvinylchloride)
TPR(Thermo Plastic Rubber)
TPU(Thermoplastic Polyurethane Elastomer)
Insert Materials
Insert material selection depends on the specific requirements of the application, including strength, durability, temperature resistance, and electrical conductivity.
- Aluminum
- Brass
- Copper
- Stainless Steel
- Steel
- Titanium
- Nickel
- Other Special Materials
Finishing
We offer a variety of finishing options to complete products made using the insert molding process. You can choose from any of the following options depending on your application requirements:
Standard Finish
Interior, non-cosmetic finish according to the geometry of the mold.
Threaded Inserts
We can install the most commonly used and popular standard inserts in UNF and metric sizes.
Laser Engraving
Engrave part numbers, designs, logos, or any other specified printing onto your parts.
Pad Printing
Application of an ink-based design to the surface.
Mold Texturing
Creating textures on the molds so that it shows on the final product. This finishing option includes matte, swirls, patterns, and lines.
As Molded
As the name suggests, the mold will remain ‘as it is’ – without any secondary texturing or polishing.
Painting
Painting the surface with standard colors or Pantone matching, including Primer and topcoat. Masking available; EMI (copper) paint.
SPI Finishes
Range of SPI finishes from Grade 3 diamond / high polish to 320 stone low polish. These Finishing options include SPI A-1, SPI A-2, SPI A-3, SPI B-1, SPI B-2, SPI B-3, SPI C-1, SPI C-2, SPI C-3, SPI D-1, SPI D-2, and SPI D-3.
Elimold for your Insert Injection Molded Project!
Insert plastic injection molding is just one aspect of our overall injection molding expertise. Our full suite of services delivers the highest quality and integrity our customers expect and deserve. Whether you need injection molding services from design to production or are seeking assistance in a single area of your development cycle, we are here to help. Our services include:
- Design for Manufacturability (DFM)— We can work with your concept or design to evaluate for not only the plastic molding process but for complete custom manufacturing of your project through the entire life of the program.
- Mold Fabrication — Our quality promise extends to mold design and fabrication, ensuring that you won’t need to work with a separate provider for this key step of your production process.
- Post Injection Molding Services – We perform parts decorating, kitting, assembly, packaging, and other custom operations.
What is Insert Molding?
Insert molding is a subset of injection molding technology that involves inserting a metal part into the mold cavity before the actual injection molding. This insertion can be done manually or through an automated process using a robotic arm. Once the insert is complete, the mold is closed and plastic is molded over the insert, turning the different parts into a single component.
Insert Molding Benefits
Recently, insert molding has changed certain industrial practices. Many industries are replacing metal parts with plastic ones because plastic is less expensive, resistant to corrosion, durable, and lightweight compared to most metals. Here are the benefits of insert molding:
- Durability: Insert molding offers high precision and enhanced product designs compared to other molding processes. Plastic parts with integrated components are more reliable and robust.
- Efficiency: Insert molding does not require separate assembly, reducing the risk of manufacturing errors. Because the insert is integrated into the molding step, it saves time and labor costs, increasing the efficiency of your entire operation.
- Cost-Efficiency: Insert molding is a cost-saving process since it allows the use of less expensive thermoplastic resins, which are more affordable than metals. It also minimizes labor costs and requirements for specialized assembly equipment.
- Lightweight: Plastic parts are generally 50% lighter than metal but are comparable in terms of strength. This has made many industries opt for plastics to replace metals. The lighter weight contributes to better fuel efficiency in automotive components and easier handling for surgical equipment.
- Size: Insert molding allows the production of smaller and thinner parts without sacrificing performance and durability.
- Material Variety: Insert molding uses a variety of common engineering thermoplastics including Nylon, PBT, PEI, PC etc. Many of these plastics are recyclable throughout their life cycle. They are also durable, versatile, and ideal for various consumer and industrial products.
- Design Variety: The process also allows different types of designs and shapes, expanding possibilities for engineering and design across many fields.
Insert Injection Molding vs Overmolding
Insert molding and overmolding are two distinctly different processes that produce their own unique types of products. The overmolding process takes place when one material is overmolded over a second material. The base layer is molded first and the additional plastic layer(s) are molded over and around the original part. This results in a single finished product. Overmolding creates a strong finished product with long service life and enhanced safety features.
Conversely, insert injection molding occurs when insert injection materials are injected into the mold cavity prior to plastic injection molding. The resulting product is a single piece with the insert encapsulated by the plastic. Plastic injection inserts provide a fast and cost-effective assembly process, producing parts with reduced size and weight.
Examples of Insert Molding Applications
Insert molding is applicable in a range of industries for a variety of applications. These are a few common insert molding examples:
- Consumer Goods: Insert molding is used to create consumer products like storage bins, toothbrushes, plastic containers, and cell phone cases.
- Automotive: In the automotive industry, gears, knobs, electrical sensors, handles, fasteners, and other automotive parts made of plastic and metal are made through insert molding.
- Medical: Plastics are easy to sterilize, so medical professionals prefer insert-molded parts for defibrillators, pacemakers, medical cables, and wiring.
- Dental: Dental professionals rely on insert-molded instruments for easy handling.
- Defense: Insert molded military products include binocular housings, decoys, battery packs, handheld communication devices, guidance systems, and more.
- Safety: Because insert molded components are easier to grip, they provide a higher level of safety for users and their operations.
- Industrial: Various industrial processes require insert-molded parts, including screws, surface mount pads, clips, spring contacts, pins, and more.
- Electrical/Electronics: Insert molding is used to encase electrical wires in rubber, which makes them waterproof and safer to handle. Insert-molded electronic products include cell phone and computer chargers.
- Beauty: In this industry, designers use insert molding to create custom packaging — for makeup brushes, perfume bottles, and compacts—that is more eye-catching and attractive to consumers.