Insert Injection Moulding – the complete service
The Company has specialized in insert moulding for more than 30 years. The process general involves inserting the metal (or other materials) component into the mould tool and then overmoulding with plastic. A strong mechanical bond is then created between the metal insert and the over moulded plastic.
The inserts are designed so that when the polymer is moulded round it, a strong fixing is achieved. A “shut-off” round the metal insert can be made, so that the metal can protrude beyond the final component.
The metal components can be inserted into the mould tool by an operator for low and medium volumes and robotically for high volume components. The Insert Moulding Company has experience in all types of insert loading
- low and medium volume by operator loading
- high volume by automatic loading
The Benefits of Insert Moulding
- Downstream Cost Reduction – the need for secondary post moulding operations can be greatly reduced by creating more complex components
- Assembly made easy – high precision metal components can be incorporated into the moldings to allow components to be screwed or clipped together
- Component consistency – operator error is eliminated achieving high levels of consistency and precision
- Component complexity – a simple moulding tool can achieve a complex component by using a well machined metal insert
- Reduced Component size and weight – by combining the physical strength of the polymer and the metal insert, the insert moulding produces a smaller and lighter component
- Component cost reduction – as a simple tool can be used with the insert, this can lead to a component being lower cost to manufacture
- Increased design flexibility – designers can appreciate the virtually unlimited configurations that the insert plastic injection moulding process allows.
Typical insert moulded components
Many industries can benefit from incorporating insert moldings into their component design. The Insert Moulding Company cover a wide industry base including military, automotive, electronics, electrical, medical, life sciences, banking equipment, aerospace, marine, furniture, building components.
The types of insert moulding manufactured include:
- Electrical and electronic pins
- Electrical and electronic contacts and connectors
- Switches
- Mechanical assemblies
- Life science sensors
- Fasteners
- Gears
Low and Medium Volume Moulding Work
The Insert Moulding Company uses both Manumould injection moulding machines and Boy and Arburg injection moulding machines for the manual loading of insert pieces.
Manumoulding
This is a hand operated machine highly suitable for low volume work. It has the considerable advantage of low tooling cost besides the tool being opened in an ideal position to allow the loading of the insert piece.
Medium Volume Insert Moulding
The Boy and Arburg machines are ideal for medium volume work.
The inserts are hand loaded into injection moulding machine. The guard is closed and the automatic moulding process begins. This allows all the control associated with sophisticated moulding equipment while retaining the flexibility of medium volume production. Often insert carriers are employed to help speed up the loading of the inserts
High Volume Moulding Work
The Insert Moulding Company can offer two alternatives to suit the customers' requirement – in-house facility (both design and manufacture) or low cost option from China
In-House facility
The equipment shown was specifically designed for the insertion of pins – loading up to 48 pins into the mould tool within a 30second cycle time. The equipment was designed and built at the company's premises
China Manufacture
The company has close ties with several high quality operations in China and closely oversees all projects. The company employs an engineer based in China to liaise with all projects.
