More about Insert Molded Plastics

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Essentially an injection molding process with an added dimension, insert molding is regularly used in the manufacture of medical equipment. During the insert molding process, prior to molding, plastic is injected into the molding cavity around an insert piece. When the molding process is complete, the insert emerges encased in plastic. Insert molded plastic can describe the plastic insert, the surrounding plastic shell, or the bonded end product.

When the insert is made from a material similar or identical to the surrounding resin, it typically forms a molecular bond. This type of bond is stronger and less likely to leak than a mechanical bond. Mechanical bonds are formed when the insert consists of a different material than the resin, such as when a metal insert is encased in plastic. In order to receive the most benefits from the insert molding procedure where a mechanical bond is expected, the insert itself should provide a surface capable of retaining the surrounding plastic.

Insert molding is sometimes known as molded insert, and it also used to mold fasteners, pins and terminals inside a part in order to eliminate post-molding costs and processes. A number of manufacturing machines are specifically designed to perform insert molding operations, and still others are effective despite being designed for somewhat different tasks. Standard injection molding devices may cause difficulty during the insert-loading phase, which may affect production performance or reduce the quality of possible part designs.

A variety of materials are used as injection molded plastics. These include numerous thermoplastics, polyethylene, polystyrene and other synthetic polymers. In general, selection of the insert material and encasing resin are determined by the application. For example, a product that will encounter extensive wear requires a durable material, while a certain temperature range encountered during use may require an entirely different plastic material.