Insert Molding is the process of molding plastic around non-plastic parts to create one part. RJCMold has almost 20 years of experience insert molding and has the equipment and knowledge for all custom insert molding needs and solutions. Our capabilities match up perfectly for customized medium/low volume components and devices in many industries including medical and industrial.
Insert molding is the process of injection molding molten plastic around any substrate or insert.
Many substrates are used in insert molding, but brass threaded inserts and bushing are the most popular. In addition, many companies make custom inserts that can be insert molded.
It is left up to the imagination when deciding what type of inserts can be over-molded. The benefit to insert molding is that parts can be mass-produced faster than whole machining parts out of metal.
Even though insert molding adds to the cycle time (typically 15 seconds per insert), it is still much faster than CNC machining a part from a solid block.
Furthermore, by insert molding metals where necessary and replacing the rest of the part with plastic will, in turn, reduce the overall weight of the part.
Did you know you can insert mold plastic parts? This process is called over-molding,and it lends itself when you need two or more different materials in the same part.
Furthermore, RJC is one of the few injection molding companies that offer over-molding and insert molding services.
Insert Molding Services From RJCmold
Insert molding combines plastics and metals into a single assembly. The process of insert molding reduces assembly and labor costs while increasing design flexibility and part performance.
Our vertical injection machines with rotary tables allow us to over mold and encapsulate inserts for electrical circuitry, fastening, and connecting. Common insert molded products include sensors, switches, connectors, and actuators.
Our insert molding presses range from 55 to 300 tons and are supported by on-press vision inspection systems, which check inserts for proper placement. If any part is not properly positioned, the system prevents the press from proceeding. This ensures the inserts are properly placed and protects the mold from damage.
RJCmold’ insert molding capabilities include manual and fully automated operations, with additional secondary forming, blanking, and 100% hipot and continuity testing.
Get easy design feedback and validation through superior quality prototype tooling. Create small batches of plastic molded parts with excellent injection molding prototypes. We excel at manufacturing prototype molds within days to ensure you perform functional tests and validate market interest.
We create high-quality production molds for high-volume plastic parts production. With high-strength, durable tool steel material, our production tooling is suitable for producing hundreds of thousands of parts. We can vary materials and construction methods according to your unique requirements.
RJCmold insert molding solutions manufacture parts with different functional and aesthetical needs. These guidelines will help improve part manufacturability, reduce lead time, and improve the part aesthetics. You can check the following standard design considerations:
Maximum Part Size
Minimum Part Size
Substrate Wall Thickness
From 0.5 to 3mm
From 0.20 to 0.12 in.
+/- 0.025 mm
+/- 0.00098 in.
Inserts can be female and male. They both can improve a product’s appearance and utility.
Provide T0, T1, T2 samples before mass production
Inspection and Certification Options
First Article Inspection, ISO 9001, ISO 13485
From mold making to sample delivery: 15-45 business days
Partner with RJC for custom insert molding
RJC offers insert molding as part of its injection molding capabilities. For a free insert molding design review and quote, please provide us with your CAD files. Our team of injection molding experts will get back to you within 24 hours. If you would like to learn more about our injection molding capabilities, please contact us for a design guide. If injection molding isn’t the best option for you, you can also try our polyurethane casting or 3D printing.
Insert molding is an injection molding process that is especially useful for parts with threaded holes. It also helps you make better wheels, pulleys, fan blades, and similar parts.
Durability: Metal inserts will guarantee thread function and mitigate wear and tear over the part’s life.
Strength: Because it’s a “one-shot” process, insert molding can produce more vital parts than overmolding and other processes.
Creating Production Parts: Insert molding is great for creating prototypes and production parts.
Materials for Insert Molding
We provide a wide range of materials for thermoplastic and inserts that can help you make insert molded parts of different industrial applications. Below are the materials used in custom plastic insert molding and common examples.
Before the insert molding process starts low or high-volume production, a high-tolerance CNC machined tooling is needed. Most commonly used materials include:
Standard plastic materials may not meet custom injection molding parts requirement. In this case, additives and fibers can be added to improve aesthetic and functional properties, providing additional features for your injection molded parts.
Plastic injection molding service comes with a wide range of materials with different properties, including impact strength, rigidity, thermal resistance, chemical resistance, etc.
The introduction of inserts onto mold cores cast using the manual or automated process leads to the plasticization of plastic pellets after closing the mold halves. Ejection of the pieces from the mold takes place after the plastic’s hardening, followed by the encapsulation of the inserts in the parts.
We offer multiple finishing options to complete the products made with the insert molding process. You can choose from any of the following depending upon your application’s requirements:
Interior, non-cosmetic finish according to the geometry of the mold.
Range of SPI finishes from Grade 3 diamond / high polish to 320 stone low polish. These Finishing options include SPI A-1, SPI A-2, SPI A-3, SPI B-1, SPI B-2, SPI B-3, SPI C-1, SPI C-2, SPI C-3, SPI D-1, SPI D-2, and SPI D-3.
We can install the most commonly used and popular standard inserts in UNF and metric sizes.
As the name suggests, the mold will remain ‘as it is’ – without any secondary texturing or polishing.
Creating textures on the molds so that it shows on the final product. This finishing option includes matte, swirls, patterns, and lines.
Engrave part numbers, designs, logos, or any other specified printing onto your parts.
Application of an ink-based design to the surface.
Painting the surface with standard colors or Pantone matching, including Primer and topcoat. Masking available; EMI (copper) paint.
Done correctly, insert molding can help
Eliminate assembly: You can make parts all at once instead of doing assembly after the fact.
Reduce costs: Insert molding costs more than standard injection molding, but the costs are usually offset because you no longer need to do post-assembly.
Lower the size and weight of the part: A plastic part with a metal insert is generally lighter than an all-metal part.
Improve reliability: Metal inserts will guarantee thread function and mitigate wear and tear over the part’s life.
Improve part strength: Because it’s a “one-shot” process, it can produce more substantial parts than overmolding and other processes.
Insert Molding Applications
Plastic insert molding is applicable in making prototypes and full products in several industries. Key industrial applications of insert molding include:
The custom plastic insert molding is suitable for making consumers good due to its functional and aesthetic benefits.
RJCmold delivers top quality plastic injection molded parts in as little as 10 business days. Our Manufacturing Partner Network can help you design and manufacture tools, dies, and molds for rapid tooling for prototyping to advanced mold making for production runs. Full injection molding capabilities including overmolding, unlimited undercuts, and internal/external threads are available.
The CNC machining process involves the use of automated rotating cutting tools and lathes to shape metal and plastic parts from blank workpieces. Capable of achieving complex geometries and angles with cost-effective speed and precision, our CNC capabilities include milling and turning services, and can scale quickly from prototypes and single parts to high-volume production requirements.
Overmolding lets you combine multiple materials into one part. One material, usually a thermoplastic elastomer (TPE/TPV), is molded onto a second material, which is often a rigid plastic. Think about your toothbrush handle where the single piece has both rigid and rubbery components. It’s a great way to make plastic parts perform and look better.
Our vetted network of partners allow us to quickly convert your 3D part data into a high-quality injection mold at top speed. We offer services from design and manufacturing for tools, dies, and molds for prototyping and production runs. Plastic blow molds, aluminum and steel tooling, 2-shot and 3-shot molding are also available. And with RJCMold, you own your own tools, so our partner network also offers mold maintenance services.
Ready to get started on your custom insert molding quote?
Insert molding is a key fabrication process across many industries and offers a wealth of benefits. RJCmold is a full-service, custom injection molding provider that works with a variety of high-performance engineered thermoplastics. We operate the latest automation and molding equipment, which allows us to compete on an international scale.Contact us today to learn more about our insert molding services, or request a quote to get started on your solution.