To create a single finished part, combining metal machined inserts with a thermoplastic during the molding process is called insert molding. The process involves placing the insert in the mold either by hand or automated, and then the molten resin gets injected into the mold, it fills in the features around the insert. The process enables the machined components to be tightly secured within the plastic resin and helps strengthen the part’s reliability. In addition, using vertical/vertical injection molding presses brings ease and convenience to the process by using the force of gravity to hold the inserts in place during the molding process.

Consolidate Your Supply Chain by Using In-House Insert Production

Finding an injection molder that performs the insert molding process that can produce the machined inserts, build the injection mold, and run production reduce the number of vendors needed to complete your project. Thus, making it easier to manage when producing these highly complex components for industries where quality matters, like a defense battery pack used for communication or a medical needle hub.

Insert molding is an advanced injection molding process, so the injection molds need to be precise to manufacture quality components. Also, ensuring the part’s integrity is not jeopardized around the inserts. Therefore, using mold fill simulation before tool fabrication becomes necessary to address any potential problems or issues in advance.  

Also, a vertical/vertical injection molding machine for manufacturing insert molded products is more efficient because it uses gravity to hold the inserts in place during the molding process.   Vertical injection molding machine also helps with production efficiency because you can have two mold bottoms running in tandem. At the same time, the inserts are loaded in one bottom half the second bottom half is performing the insert molding process.

So all pieces of the process must be created using the most current and accurate manufacturing technology, starting with manufacturing the inserts, fabricating the correct injection mold, and producing quality components. Choosing a single vendor to do all of this reduces your supply chain and headaches.

No Need to Sacrifice Quality for Precision Screw Machined Inserts

CNC Swiss screw machining can make small, slender, complex, and precise components due it the machine’s unique design. In addition, these automatic lathes have sophisticated controls to streamline the machining process and can be used with a wide variety of materials and grades of materials depending on the required function of the product or application.

Variety of Materials for Screw Machined Inserts Available

Review the different materials available to manufacture your inserts.

  • Aluminum – a heat treatable material that has high mechanical properties to relieve stress corrosion and cracking
  • Plastics – offers a wide variety of materials depending on your product needs. Materials include Acetal, Delrin, nylon, Teflon, and PEEK.
  • Stainless Steel – includes many different grades, such as medical-grade material. These offer corrosion resistance and are heat treatable if required.
  • Carbon Steel- is steel with low carbon content used for applications requiring close tolerances and threading applications like bushings, inserts, couplings, pins, studs, and screws.
  • Brass and Copper – is used for several electronic hardware, contacts, and fittings. Copper is also excellent for electrical conductivity.
  • Alloy Steel – a material that is heat treatable and used to machine parts for higher stress applications.   It provides extreme harden-ability and internal strength.
  • Titanium – a high strength, lightweight, biocompatible material used for medical implants
  • Molybdenum – offers a heat-resistant material used in missiles, aircraft parts, and heating elements.
  • Nickel Alloy – the material offers a lustrous silver color component with corrosion resistance and strength. Typical applications include optical parts, springs, surgical instruments, resistors, and contacts.
  • Monel™ - the material is nickel with high strength and excellent corrosion resistance over a wide range of temperatures and conditions.

Today’s technology is making it possible to create the highest quality manufactured products. So, when looking into the future, consider Crescent Industries for your next insert molding project. They can manufacture the metal inserts, build the injection mold, and run production.

Read the Complete Guide to  Plastic Injection Molding

Topics: Swiss Screw Machining, insert molding