Puide Pillar,Push Rod Tubes, Ejector Guide Pin, Lifetime Carbide Punch and Die Set Dongguan Hao Chen Precision Industry Co., Ltd. , https://www.howmolds.comWhat is Insert Molding?
Insert molding is a process in which pre-formed components are placed into a mold before the plastic is injected, resulting in a single, integrated part. For example, threaded inserts are commonly molded into fasteners, and metal contact pins are often inserted into connectors. This method not only reduces the cost of individual parts but also eliminates the need for assembly, leading to significant cost savings.
By combining the lightweight and flexible properties of plastic with the strength and rigidity of metal, insert molding allows for the creation of more durable and reliable products. However, if the components are custom-made rather than standard off-the-shelf parts, this can add time and expense to the overall process.
When to Use Insert Molding
You should consider using insert molding when your design requires:
- A metal component
- Threaded inserts
- A sub-assembly (such as embedded wires, electronic parts, or circuit boards)
How to Use Insert Molding
Insert molding offers a creative approach to product design. Components like Right Angle Pin Headers can be mass-produced as sub-assemblies, making it easier to place them into the molding machine without individually positioning each pin. This leads to a streamlined one-step process that saves both time and money.
Before starting, make sure you have all the necessary files ready for engineers or designers to reference. The final design must include CAD models of the inserts to determine how much space they occupy. This helps assess the impact on structural integrity. Any Design for Manufacturability (DFM) considerations should also be documented to ensure quality control before production begins.
What is Overmolding?
Overmolding is a type of insert molding where a second layer of plastic is molded over an existing part. The first component is created in one injection mold and then placed into a second mold to form the final product. This technique is commonly used in handles, where a softer plastic is molded over a rigid core to provide a more comfortable grip.
By combining multiple materials into a single component, overmolding reduces assembly costs and eliminates the need for adhesives or other bonding agents. It also enables the creation of complex products with varying textures, colors, or properties. For instance, soft seals can be embedded within a product using this method.
Another common application is in pin assemblies, where multiple pins can be molded at once instead of being placed individually, ensuring accuracy and saving time.
However, maintaining the right temperature during the process is crucial, as improper conditions can lead to delamination. Since overmolding typically requires two molds or a more complex two-shot system, it tends to be more expensive than traditional single-part molding. That said, when comparing the cost of producing two separate parts and assembling them versus using overmolding, the latter is often more cost-effective.
When to Use Overmolding
You should consider overmolding when your application requires:
- Different thermal or electrical properties
- Shock absorption or vibration damping
- Multiple colors
- A comfortable, non-slip grip
- Embedded soft seals
Overmolded parts can also be customized further if needed. Their durability makes them ideal for use in the automotive industry, where contact pins can be overmolded with plastic or rubber for use in sensors, control units, or infotainment systems.
Choosing between insert molding and overmolding depends on the specific needs of your project. While insert molding is generally more cost-effective and faster, custom designs may increase the overall cost and complexity.
Whether you're looking for insert-molded or overmolded connectors, or complete assemblies, Bead Electronics has extensive experience providing high-quality pins for a wide range of applications in industries such as automotive, telecom, aerospace, industrial, and medical.
Bead's contact pins can be used in power, signal, or electro-mechanical applications as part of an insert-molded or overmolded connector. Contact us today to speak with a specialist!
The Difference Between Insert Molding and Overmolding;Â What You Need to Know
Molds have transformed the manufacturing landscape, enabling suppliers to produce identical parts quickly and efficiently. Injection molding, a process where molten plastic is injected into a mold to create components, is widely used across industries such as automotive, aerospace, industrial, and medical. This technique can be further divided into two main types: insert molding and overmolding.