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Insert Molding

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EVCO Plastics has many years of experience as a custom plastic insert molder.

Plastic injection insert molding is a plastic injection molding process in which thermoplastic material is molded around an insert piece or pieces placed in the plastic injection molding cavity, resulting in a single strongly bonded, integrated assembly, with the insert or inserts encapsulated by the plastic. Inserts can be metal, another plastic, ceramic or just about any substance that can withstand the plastic injection molding process.

Some of the first insert molding applications were for placing threaded inserts into molded parts and encapsulating wire plug connections on electrical cords. Current custom insert molding applications are wide ranging with few limitations on material combinations, including:

Medical devices and instruments, such as needle hubs and tube valves

Knobs for appliances, controls and assemblies

Encapsulated electronic devices and electrical components

Military equipment

Threaded fasteners

Encapsulated bushings, tubes, studs, and posted

Plastic injection insert molding is an effective alternative to assemblies manufactured using soldering, adhesives or fasteners, with benefits including:

Reduced assembly and labor costs

Molded as one assembly

Reduced size and weight

Insert molding allows for reduction of part size and weight because parts are joined with strong, light weight plastic resin and fasters or connectors are eliminated.

Improved component reliability

Insert molding of components ensures proper alignment, prevents loosening and the plastic resin can provide improved resistance to vibration and shock

Improved part strength and structure

Insert molding combines the physical strength of the plastic resin and insert to produce one seamless plastic part

Enhanced design flexibility

Custom plastic insert molding allows for almost unlimited configurations and material combinations

Consolidation of components

Insert molded components enable part and inventory cost reductions

Another application of the plastic injection insert molding technology is in-mold decorating (IMD) and in-mold labeling (IML), in which decorated or printed film is inserted into the mold cavity and the plastic resin injected against the film, resulting in a labeled or decorated part that is durable and cost effective.

Proper mold design and construction are critically important in insert molding to maintain part tolerances and tooling reliability. EVCO Plastics often employs robotic automation in the insert molding process for fast and precise placement of inserts.

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