
ELIMINATE UNNECESSARY SECONDARY OPERATIONS with insert molding

ISO 13485, ISO 9001:2015, AC8160, ISO 14001:2015
What is insert molding?
Insert molding is a specialized plastic injection molding process where pre-formed components, often made of metal or other materials, are placed into a mold, and then molten plastic is injected around them to create a single, integrated part. The insert, which could be something like a metal screw, pin, or electronic component, becomes a permanent part of the molded plastic product.

Plastic injection molding techniques
The benefits of Insert Molding
- Consistency
Inserts add part consistency by eliminating operator error.
- Stability
Inserts increase part functionality, stability and strength.
- Reduce size & weight
With the combination of the strength of the polymer and the metal insert, the insert molding process produces a smaller and lighter component.
- Design flexibility
Insert molding offers industrial designers a host of options.
How insert molding could benefit your project

Applications for insert molding
fasteners
Threaded Inserts: Metal inserts with threads are molded into plastic parts to provide strong, durable threads for fasteners, often used in automotive and consumer electronics applications.
Reinforcements: Metal or other strong materials are molded into plastic parts to reinforce areas that experience high stress, improving the overall strength and durability of the product.
Embedded Fasteners: Plastic parts with embedded metal fasteners allow for easy assembly and disassembly, used in various consumer goods, electronics, and automotive applications.

Electrical components
Connectors and Switches: Insert molding is used to encase metal contacts or circuitry within a plastic housing, commonly seen in electrical connectors, switches, and sensor housings.
Electronic Components: Protects sensitive electronic parts by encasing them in plastic, providing insulation and structural integrity.
Medical Devices
Surgical Instruments: Metal parts like needles or blades are molded into plastic handles or housings to create ergonomic, single-use medical devices.
Implants and Prosthetics: Insert molding can be used to combine biocompatible materials with plastic to create medical implants and prosthetic devices.
Automotive Parts
Mounting Components: Metal brackets or bushings are insert molded into plastic components for mounting in vehicles, ensuring durability and reducing assembly steps.
Hybrid Components: Parts like gear shifters or dashboards may use insert molding to integrate metal and plastic for enhanced functionality and aesthetics.

Consumer Products
Handles and Knobs: Metal inserts are molded into plastic handles or knobs for strength and aesthetic appeal, commonly used in kitchen appliances and tools.
Wearable Devices: Metal components in smartwatches or fitness trackers are often insert molded to integrate electronic functionality with durable, lightweight plastic casings.
Conclusion
Saving time and saving money are vital keys to growing your business and your profits. PTI’s insert molding does both. This method is a precision molding process that feeds resin into a heated barrel where it is then mixed and injected into a mold cavity that features a pre-placed insert where the resin cools and hardens.
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Design For Manufacturing Guide
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Mold Design
Mold Design is a crucial step in the injection molding process. Once you’ve finalized your part in CAD software for fit and function, it must then be transformed into a design for molding to ensure the capture of all the specified details. In some cases, certain features of the part design may not be manufacturable via the injection molding process.
At PTI, we collaborate with you to achieve the best possible design for manufacturability. In fact, we have a FREE guide to help you with this.

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