High-Performance Insert Molding Solutions
Insert Molding dominates electronics, automotive, and energy sectors for hybrid assemblies. Typical applications:
- Threaded metal fasteners in plastic
- Sensor-embedded housings
- Circuit board encapsulation
- Automotive fluid system hybrids
- Reinforced electrical contacts
- Valve component assemblies
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Service
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Manual Insert MoldingRequires manual placement of inserts into molds before injection (±0.5mm tolerance). Ideal for low-volume prototypes and complex geometries like surgical tool components. -
Automated Insert MoldingUses robotics for high-speed insert placement (±0.1mm tolerance). Dominates mass production of automotive fasteners and micro-USB connectors. -
Semi-Automated Insert MoldingCombines manual loading with mechanized molding (±0.3mm tolerance). Cost-effective for mid-volume medical housings requiring ISO cleanliness standards. -
Co-MoldingBonds dissimilar materials (e.g., metal+TPE) in single cycle (±0.2mm tolerance). Critical for ergonomic power tool grips and aerospace composite fittings.
Our Expert Insert Molding Parts
Precisely encapsulating metal/ceramic inserts (M2 screws, sensors, connectors) with 0.01mm positional tolerance. Automated vision inspection ensures 100% insert alignment verification for electrical and mechatronic assemblies.
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10+ Years of CNC Machining ServicesTight Tolerance of 0.005mmInstant Quote As fast as 2 Hours2 working days deliver time at fastest -
210+ Years of CNC Machining ServicesTight Tolerance of 0.005mmInstant Quote As fast as 2 Hours2 working days deliver time at fastest -
310+ Years of CNC Machining ServicesTight Tolerance of 0.005mmInstant Quote As fast as 2 Hours2 working days deliver time at fastest
Insert Molding Materials
Encapsulating brass/steel inserts in high-flow materials (PP, POM) with <0.1mm warpage. Special formulations prevent cracking around metal components in electrical connectors and sensor housings after thermal cycling.
Metals
Lightweight, high thermal conductivity, Excellent Machinability, Superior Dimensional Stability, Tight-Tolerance Capable, Perfect for Complex CNC Milling and Turning.
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Lead Time: < 5 days
Tolerances: ±0.005″ (±0.125mm)
Max part size: 200 cm x 80 cm x 100 cm
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Tolerances: ±0.005″ (±0.125mm)
Max part size: 200 cm x 80 cm x 100 cm
Golden aesthetic, good machinability, moderate corrosion resistance, often used for decorative hardware.
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Superior wear resistance, seawater corrosion resistance, classic metallic luster, commonly cast.
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High thermal/electrical conductivity, antimicrobial surface, develops natural patina over time.
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High strength-to-weight ratio, magnetic properties, requires coating for rust prevention.
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Chromium-enhanced corrosion resistance, heat-resistant, maintains strength in extreme conditions.
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Extremely lightweight (67% aluminum density), good vibration damping, requires surface treatment.
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Aerospace-grade strength, biocompatible, seawater corrosion resistance, difficult to machine.
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Plastics
Fast-flowing melt, low shrinkage (0.4-0.7%), requires pre-drying (80°C/4h), ideal for automotive dashboards and consumer electronics housings.
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High melt viscosity (300-350°C processing), moisture-sensitive (0.02% max), optical-grade clarity for LED lenses and medical device components.
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High mold temperature (60-80°C) reduces internal stress, low warpage, replaces glass in automotive taillights and cosmetic packaging.
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Crystallization-sensitive cooling (80-120°C mold), high dimensional stability, precision gears and fuel system valves.
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Moisture absorption (2.5-3.5%) requires post-molding annealing, self-lubricating bushings and automotive cable ties.
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Low melt strength (LDPE: 160-240°C), high flow rate for thin-wall containers and chemical-resistant pipeline fittings.
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Extreme processing temps (380-400°C), low shrinkage (0.1-0.3%), aerospace bushings and surgical sterilization trays.
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Fast crystallization (mold temp 60-80°C), glass-fiber reinforced connectors in automotive ECU housings.
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Low density (0.9g/cm³), living hinge capability, disposable syringes and automotive HVAC ducts.
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Non-melt flow (sintering required), ultra-low friction coatings for semiconductor seals and non-stick cookware linings.
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Insert Molding Tolerances and Standards
For your convenience and to solve your problem more efficiently, refer to the following information to improve part manufacturability and reduce lead times. Let’s unlock the potential of your insert molding project.
Insert Molding Surface Finishes
Looking for the right finish? Choose from 20+ options to meet both your functional and aesthetic needs.
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As MachinedDescription: Standard finish with surface roughness of 3.2 μm (126 μin), removes sharp edges and deburrs parts cleanly. Key Use: Functional parts requiring no post-processing (e.g., brackets, gears). Process Tolerance: Dimensional ±0.1 mm, Ra 3.2±0.5 μm Process Specifications: ISO 2768-m standard, burr height ≤0.05 mm
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AnodizingDescription: Electrochemical oxide layer for corrosion resistance and aesthetics. Process Compatibility: Post-machining surface treatment Key Use: Aerospace components, consumer electronics (e.g., phone frames). Process Tolerance: Coating thickness 10-25 μm±2 μm, color consistency ΔE≤1.5 Process Specifications: MIL-A-8625 or ISO 7599, sealing pH 5.5-6.5
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AlodineDescription: Chemical film for corrosion protection and paint adhesion. Process Compatibility: Post-cleaning chemical immersion Key Use: Aviation and automotive electrical housings. Process Tolerance: Film thickness 0.5-3 μm, visual uniformity Process Specifications: Immersion time 3-10 min, bath temp. 20-30℃
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Black OxideDescription: Thin magnetite layer for corrosion resistance and reduced glare. Process Compatibility: Post-machining chemical treatment Key Use: Tools, firearms, automotive fasteners. Process Tolerance: Coating thickness 0.5-1.5 μm, salt spray ≥24 hrs Process Specifications: Alkaline bath pH 13-14, process time 5-30 min
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BrushingDescription: Linear abrasive finish for decorative texture. Process Compatibility: Manual/CNC abrasive belts Key Use: Appliance panels, architectural trims. Process Tolerance: Texture depth 0.05-0.2 mm, angle deviation ≤5° Process Specifications: Abrasive belt grit 80-240, feed speed 10-30 m/min
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EtchingDescription: Chemical/mechanical removal for micro-texturing or marking. Process Compatibility: Laser/chemical masking Key Use: Circuit boards, decorative logos. Process Tolerance: Etch depth 0.01-0.5 mm±5%, alignment ±0.1 mm Process Specifications: Etchant concentration 10-30%, laser power 20-100 W
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Electroless PlatingDescription: Uniform metal coating (e.g., nickel) without electricity. Process Compatibility: Chemical bath deposition Key Use: Wear-resistant industrial valves, connectors. Process Tolerance: Coating thickness 5-50 μm±5%, porosity ≤5/cm² Process Specifications: Bath temp. 85-95℃, pH 4.5-5.5
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ElectroplatingDescription: Electrochemical metal coating (e.g., chrome, zinc) for durability. Process Compatibility: Post-machining electrodeposition Key Use: Automotive trim, jewelry. Process Tolerance: Coating thickness 5-25 μm±2 μm, adhesion ≥4B (ASTM B571) Process Specifications: Current density 1-10 A/dm², bath temp. 40-60℃
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ElectrophoreticDescription: Polymer coating via electric field for corrosion resistance. Process Compatibility: Post-cleaning immersion Key Use: Automotive frames, HVAC components. Process Tolerance: Coating thickness 15-30 μm±3 μm, edge coverage ≥80% Process Specifications: Voltage 50-300 V, cure 160-200℃×20 min
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GrindingDescription: Precision abrasive finish for tight tolerances. Process Compatibility: Surface/cylindrical grinding Key Use: Bearing races, hydraulic shafts. Process Tolerance: Dimensional ±0.005 mm, Ra 0.4-0.8 μm Process Specifications: Wheel grit 60-120, coolant flow 5-20 L/min
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Heat TreatmentDescription: Thermal process to alter material hardness/toughness. Process Compatibility: Post-machining quenching/tempering Key Use: Gears, cutting tools. Process Tolerance: Hardness HRC 45-60±2, distortion ≤0.1% Process Specifications: Quench temp. 800-1000℃, temper time 1-4 hrs
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KnurlingDescription: Diamond or linear pattern for improved grip. Process Compatibility: CNC lathe rolling Key Use: Handles, adjustment knobs. Process Tolerance: Pattern depth 0.2-0.5 mm, pitch ±0.05 mm Process Specifications: Roller pressure 200-500 N, feed 10-50 mm/min
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Laser EngravingDescription: Permanent marking via laser ablation. Process Compatibility: Post-processing laser systems Materials: Metals, plastics, wood Key Use: Serial numbers, branding on industrial parts.
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OvermoldingDescription: Molding soft material (TPU/silicone) over rigid inserts. Process Compatibility: Injection molding Materials: Plastics, metals (as inserts) Key Use: Ergonomic handles, waterproof seals. Process Tolerance: Overmold thickness 1-5 mm±0.2 mm, bond strength ≥5 MPa Process Specifications: Injection pressure >5 MPa, mold temp. 40-80℃
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PolishingDescription: Mirror-like finish via abrasive compounds. Process Compatibility: Manual/robotic buffing Key Use: Medical instruments, luxury fixtures. Process Tolerance: Ra 0.025-0.1 μm, gloss ≥90 GU Process Specifications: Wheel speed 1000-3000 rpm, compound grit 2000-5000
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PassivationDescription: Acid treatment to remove free iron and enhance corrosion resistance. Process Compatibility: Post-cleaning chemical immersion Key Use: Surgical tools, food processing equipment. Process Tolerance: Film thickness 0.001-0.01 μm, salt spray ≥96 hrs Process Specifications: Nitric acid 20-50%, process time 20-60 min
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Powder CoatingDescription: Electrostatic polymer powder cured into durable film. Process Compatibility: Post-cleaning spray and bake Key Use: Outdoor furniture, automotive wheels. Process Tolerance: Coating thickness 60-120 μm±10 μm, ΔE≤1.0 Process Specifications: Voltage 30-90 kV, cure 180-200℃×15 min
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PhosphatingDescription: Phosphate layer for lubrication and paint adhesion. Process Compatibility: Chemical immersion Key Use: Engine components, firearm parts. Process Tolerance: Coating weight 2-5 g/m², crystal size ≤5 μm Process Specifications: Bath pH 2-4, process temp. 40-70℃
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PaintingDescription: Liquid coating for color and protection. Process Compatibility: Spraying/dipping Materials: Metals, plastics Key Use: Consumer electronics, automotive body panels. Process Tolerance: Coating thickness 20-50 μm±5 μm, adhesion ≥3B (ASTM D3359) Process Specifications: Spray pressure 0.3-0.6 MPa, cure 80-120℃×30 min
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Sand blastingDescription: Abrasive jet finish for uniform matte texture. Process Compatibility: Post-machining blasting Materials: Metals, glass, stone Key Use: Architectural facades, engine blocks. Process Tolerance: Ra 1.6-6.3 μm, coverage ≥95% Process Specifications: Grit size 80-120, air pressure 0.4-0.7 MPa
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What is Insert Molding?How Does Insert Molding Work?
Insert Molding is a specialized injection molding process where pre-fabricated inserts (e.g., metal parts, threaded fasteners, or electronic components) are embedded into molten plastic to form a single, unified part. This method integrates dissimilar materials seamlessly, enhancing structural integrity and functionality in applications like electrical connectors, automotive sensors, and medical devices.
Insert Preparation:Inserts (e.g., brass threads, metal pins, or ceramic substrates) are manufactured via machining, stamping, or 3D printing.
Surfaces may be treated (e.g., roughening or coating) to improve adhesion with the plastic.
Mold Setup:Inserts are manually or robotically placed into designated cavities within the injection mold.
Precision alignment ensures the insert remains fixed during plastic injection.
Injection Molding:Molten thermoplastic (e.g., nylon, ABS, or PEEK) is injected into the mold, encapsulating the insert under controlled temperature and pressure.Cooling systems solidify the plastic around the insert, forming a permanent bond.
Post-Processing:Excess material (flash) is trimmed, and parts are inspected for bonding quality and dimensional accuracy.
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CNC MachiningWe specialize in manufacturing custom prototypes and end-use parts with precise and complex designs through CNC milling,CNC turning, and CNC precision machining. -
Sheet Metal FabricationWe expert in the flexible manufacture of sheet metal prototypes and precision parts through laser cutting, stamping, metal bending, metal welding, riveting, embossing, flanging and tapping, chamfering and other processes. -
Injection Molding ServicesWorldsoaring provides plastic injection molding, rapid and production tooling, overmolding, and insert molding service. No MOQ required, all while maintaining high-quality and precision molding products. -
More ServicesSLA, HP MJF, SLS, SLM technologies for functional prototyping and low-volume production. We manufacture 3d printed parts at competitive price. -
SolutionsSLA, HP MJF, SLS, SLM technologies for functional prototyping and low-volume production. We manufacture 3d printed parts at competitive price.
Success Stories of Insert Molding Projects
FAQs
What materials are used in insert molding?
Insert molding utilizes engineering-grade thermoplastics (nylon, PEEK, ABS) paired with metal inserts (stainless steel, brass, aluminum). The process
requires materials with compatible thermal expansion coefficients and bonding characteristics to ensure structural integrity under operational stresses.
What is the difference between insert molding and overmolding?
While both processes create multi-material components, insert molding embeds pre-formed metal/plastic inserts during injection, primarily for
structural enhancement. Overmolding sequentially molds thermoplastic elastomers (TPE) over substrates to improve grip or aesthetics. Insert
molding accommodates various processes, whereas overmolding is exclusively injection-based.
How do you design an insert molding?
Insert molding design requires strategic planning of part specifications, material selection, and process parameters. Key considerations include:
defining mechanical/thermal requirements, selecting compatible metal/plastic combinations, optimizing insert geometry for mold integration,
and validating through prototyping. The process demands precise control of injection parameters to ensure proper material bonding and
dimensional accuracy.
