Insert molding is an injection molding manufacturing process in which a mold is filled with a pre-prepared insert of different material and then injected with plastic resin, and the molten material is joined with the insert and cured to make an integrated product. There are many advantages to this availability

One big advantage of insert molding is that it affords enhanced product design and manufacturing. The precision with which you can place inserts into a mold design cannot be achieved with other molding processes. In short, plastic parts with integrated components are much stronger and more reliable.

Also, since there is no assembly involved in this one-step process, there is less opportunity for error in manufacturing.

Plastic parts can be up to 50 percent lighter than their metal counterparts. This, combined with strength, is one of the primary reasons that industries are turning to plastic molding for parts. From fuel efficiency to better ease-of-use for surgical instruments, lighter weight enhances performance and functionality.

The insert molding process allows the production of parts that are much smaller or thinner, without sacrificing durability or performance. A simple example is vehicle components. Thinner door and console parts mean more room in the interior of the car.

Pins, screws, brass inserts can be automatically placed into a plastic mold, like custom connector, which then hardens to keep them in place.

Insert molding achieves cost savings in two ways. First, they allow the use of much cheaper materials. In general, resins are much more affordable than metals.

Also, molding production processes themselves are cost-effective. Insert molding is a one-step process. Unlike other types of molding, assembly and labor costs can be streamlined.

Insert molding eliminates a second assembly step in the manufacturing process. The insertion of metal or other components is integrated with the molding step, so there is no need for a stand-alone task. This saves time and money associated with labor and specialized equipment for these processes.

Insert molding can use many different types of plastic resins in the process. These including thermoplastics, which are eco-friendly since you can recycle them. The most common thermoplastics are polyethylene, polystyrene, and nylon. These are all lightweight, durable, and ideal for consumer products to heavy-duty industrial ones.

Other common materials are thermosets, such as epoxy, and elastomers. Natural rubber, which is both strong and flexible, is a good example of the latter.

Besides materials, insert molding allows many different types of shapes and designs for its parts. This is often not achievable using metals. It’s obvious how unlimited configurations have expanded the range of possibilities for engineering and design in different industries.

Because of the advantages cited above, we are seeing many industries shifting toward insert molding for plastic components. One example is automotive manufacturing and trucking. This is due to weight reduction, which means better fuel economy. This has been a huge asset in manufacturers continuing to meet federal fuel-efficiency standards.

Insert moulding is used to create many things such as wire spools, packaging, bottle caps, automotive parts and components, toys, pocket combs, some musical instruments (and parts of them), one-piece chairs and small tables, storage containers, mechanical parts (including gears), and most other plastic products.