Insert Injection Molding Plastics

An insert is considered anything that can withstand the injection molding process. In most cases, inserts are conductive metals such as copper, brass, or steel, and usually in the form of metal stampings, screw machined and cold headed parts, wound coils, and wires. Also, items made of ceramic, die castings, and even molded parts are often used as inserts. Components unique to their application can possess molded features. For example, a hypodermic needle may be an insert in a medical application, a flexible circuit could be overmolded for a printer component, or an electronic subcomponent can be converted to surface mount technology.

The process itself begins with the same process used in injection molding. Solid pellets of raw material are melted and extruded into a mold, the plastic solidifies, the press opens, and the molded part is ejected. In insert molding, the insert is placed into the mold before the raw material is injected. Then, as the molten plastic fills the mold, it flows into undercut features in the insert, such as holes, grooves, or bosses. The insert is anchored much more securely than if it were assembled to a previously molded component. For extreme applications, high heat engineering thermoplastics are used. These materials withstand temperatures beyond 600F, and display excellent physical, electrical, and chemical properties for use in harsh environments (i.e. engine components). Mid-range materials come at a lower cost and are still suitable for some high heat applications (i.e. soldering processes, high current). And commodity resins (nylon, polypropylene, etc.) are now compounded in ways to satisfy tough requirements, while providing even more economy. KEYWORDS for this process: moulds, moulding, moulders, molds, molders


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