Professional Insert Injection Molding Expert

Professional Insert Injection Mold Manufacturer

Design is a main factor for the smoothly running of insert molding, the mold should entertain the inserts, and the insert must be fully designed and manufactured to perfectly fit the plastic part. Kemal uses the Europe and American standards for your mold design and manufacturing. In order to guarantee the long mold life. Kemal use the harden steel for your insert injection molds, and provide the steel and heat-treat certification for your insert injection molds. So you can completely trust the mold quality.

Insert Injection Molding Parts

Kemal has an efficient experience for manufacturing the insert molding parts for our customers.

And provide strength or the power of durability for the insert injection molding in a more efficient manner. Different kinds materials of inserts will have different ways during the injection process.

Here are some samples for your reference, please contact us freely if you need any help or support.

Why choose Kemal make Insert Injection Molding

Kemal has many up-to-date types of equipment to manufacture your insert injection mold, such as Makino & Mikron CNC milling machines, Sodick Wire EDM, Charmilles EDM machines, etc.

Kemal always uses the European and American standards for your insert mold design and manufacturing.

So you can blankly trust every Kemal mold quality.

In order to guarantee the long mold life, Kemal uses the hardened steel for your insert injection molds.

We will provide the steel certification and heat-treat certification for your insert injection molds.

Kemal provides after-sales service at your factory if your insert injection mold has any problem.

We will be 7/24 online to support your business.

Contact Our Professional Team

Kemal Your reliable Insert Injection Molding Manufacturer

Kemal is an insert injection molding manufacturer in China for over 20 years. For any of your insert injection molding orders, we will arrange at least 15 professional engineers to support you.

Our professional technical team will help you optimize the structure of your product to improve performance and increase strength. The result is a significant reduction in assembly time and labor costs.

If you plan to develop your insert injection mold, we have our own vertical injection machine and will test your mold on the machine before shipment. Of course, if you also need us to manufacture your insert injection mold parts, we have a good capability to manufacture perfect parts for you.

Our design team will provide free solutions for your insert injection molds and parts. This will guarantee the project move forward smoothly.

Kemal provides after-sales service at your factory if your insert injection mold has any problem.

you will always get a fast response from our professional team within one day.

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INSERT INJECTION MOLDING: THE ULTIMATE FAQ GUIDE

As the professional Insert injection molding manufacturer with 24 years experience. Kemal pays 100% passion to serve you well.
Here is the FAQ list of the Insert injection molding. You could check any question about the Insert injection molding that you would like to know.

Such as The benefit of injection molding. The general defects of insert injection molding. What should be paid attention to in the mold design of the custom insert injection molding system, Etc?

For further communication just feel free to Contact Kemal Team.

Here is the FAQ List:

1.What is Insert Molding?

2.What are the advantages of Insert injection molding?

3.What are the advantages of the Insert Molding process over the thermal molding process?

4.Are the inserts in the Insert Injection Molding process all metal parts?

5.What are the steps of Mobile positioning Insert Injection Molding?

6.What are the advantages of active positioning Insert Injection Molding over common ones?

7.What should be paid attention to in the mold design of the custom insert injection molding system?

8.What steps of insert injection molding are, when the metal insert acts as an electrical connection contact?

9.What are the main features of insert injection molding technology for metal inserts?

10.What are the general defects of insert injection molding of metal inserts?

11.What’s the difference between Insert Molding VS Over molding?

12.What industry Insert molding is mainly used in?

13.Why the Insert molding process is used for the complex integrated metal and plastic product?

14.Why the insert molding process generally used in the production of electrical products?

16.What factors should we consider before Insert molds design for Products prone to damage, such as Glass, coil, electrical parts?

17.What do we do if we want to seal the insert completely into the plastics materials?

18.Why should metal inserts be positioned when they are molded?

19.Why is insert molding widely used in the production of automotive plastic products?

20. In the plastics insert molding, How can we enhance the bonding strength between metal inserts and plastic inserts?

21.What are the special considerations for Insert Injection Molding?

22.Why Kemal was chosen to produce the insert injection molding mold?

 

1.What is Insert Molding?

Insert molding is a molding process in which plastic is injected after a prepared different material, and the insert is loaded into the mold.
Besides that,the fused plastic is perfectly joined and cured together with the insert.
The insert molding process can be used for the production of integrated products.
The integrated products are always meet the basic functions of electrical products.
Insert molding could adopt in various Industries, Such as the toy industry, home furnishing industry, automobile industry, home appliance industry, and so on.
Insert Molding is a very widely used process.
The Kemal team was familiar with the technical details of the Insert Molding.

2. What are the advantages of Insert injection molding?

The advantages of Insert injection molding are as below:
Insert injection molding could simplify the process of the molding.
For example, The flexible forming on the rubber seal pad can save the complicated procedure of arranging the sealing circle.
In general, if the plastic parts and embedded parts of the product are processed separately, it will not only increase the processing time of the product but also increase the labor cost of processing.
In addition, the final product quality can not be guaranteed, and the rework production will increase the processing cost.
Therefore, Insert Injection molding is a processing process that can improve the processing efficiency, reduce the production cost, and reduce the scrap rate.

3.What are the advantages of the Insert Molding process over the thermal molding process?

The advantages of the Insert Molding process over the thermal molding process are as below:
Compared with the hot-melt molding process, the gap of the Insert molding process can be designed to be narrower, the joint of the molten material and the metal molding can be more fit, and the composite molding has higher reliability.
So, the insert Molding is applied more to products that need to fit the product and the assembly together.
Because the plastic Insert Molding products, which are more waterproof and dustproof, the appearance is of better quality.
The combined products have better commercial value.

4.Are the inserts in the Insert Injection Molding process all metal parts?

The inserts in the Insert Injection Molding process are not all metal parts.
They are not only a metal insert. The wire, plastic, glass, cloth, paper, wood lines electrical parts, copper, iron, steel, aluminum, ceramics, and others could be an Insert part.
The Insert Injection Molding implemented the function of combining the different materials with the plastic parts.
The Insert Injection Molding process allows product developers to be bold in developing new products.
The Insert Injection Molding Bring a different and novel product experience to consumers. The Insert Injection Molding broadened the field of product development, promoted the development of the market, and enhanced the confidence for the production of the enterprise.

5.What are the steps of Mobile positioning Insert Injection Molding?

The steps of Mobile positioning Insert Injection Molding are as below:

First step:Place the metal parts in the fixed mold cavity and fix the positioning,Ensure that metal parts are placed in the correct location and direction, so as to reduce the rejection rate of products.

In the second step:The movable mold is closed with the fixed mold, and the movable part supports the metal part. At this time, the movable part is the key component, and the quality stability must be guaranteed to support the Metal Part.

The third step:The glue filling,at this point, the injection must be slow to make the surface firm and smooth, and the metal part tightly injection molding.

Step Four: Loosen the active insert,Delayed filling with glue,At this time, must pay attention to wait for the glue to cool firm before loosening.

Step Five:Cool down and demould. At this point must pay attention to the adhesive cooling firm before stripping.

6.What are the advantages of active positioning Insert Injection Molding over common ones?

The advantages of active positioning Insert Injection Molding over common ones are as below:
The active positioning Insert Injection Moulding can prevent metal parts from displacement during the injection molding process.
Keep a fixed position when filling with glue, When the filling is complete, cool the mold release without leaving positioning holes in the plastic parts.
The active positioning Insert Injection Molding can not only improve the appearance of the product but also reduce the defective rate.
Besides that The active positioning Insert Injection Molding without leaving positioning holes in the plastic parts, Which improves the waterproof and dustproof function of the product and simplifies the production process.

7. What should be paid attention to in the mold design of the custom insert injection molding system?

(1) It is easy to produce an uneven shrinkage rate in the forming of metal inserts. Limit tests should be carried out on the shape and dimensional accuracy of important parts in advance.

(2) In the process of insert molding, metal inserts are easy to deform and shift, so the mold composition and mold shape design that is easy to keep the metal inserts should be fully considered.

(3) To confirm that metal inserts whether the need to be preheated and dried.

(4) Another important factor is to consider the mold kernel material, Normally,Lower hardness material is inserted into the main mold kernel to seal the adhesive.

8.What steps of insert injection molding are, when the metal insert acts as an electrical connection contact?

The steps of insert injection molding are as follows when the metal insert acts as an electrical connection contact:
When metal inserts act as electrical connectors, the position accuracy is required to be higher.
In the process of plastics insert injection molding, the secondary injection molding process is generally adopted.
The first injection molding mainly supported and fixed the metal line, When the first injection molding working, it should support and fixed the metal line well.
The second time is used to shape the whole product. When the second injection molding working, It should pay attention to cool down and demould the finish products.

 

9.What are the main features of insert injection molding technology for metal inserts?

(1) Before the clamping, Make sure that the metal insert is stable in the mold cavity.
If metal inserts float or fall off, it will lead to the final molding parts can not be used normally, and even cause mold damage.
Therefore, it is necessary to adopt various positioning devices to ensure the accurate positioning of metal inserts, Which increased the complexity of mold structure.
In addition, higher requirements are put forward for the dimension accuracy of the layout and positioning device in the cooling water channel.

(2) The choice of material for metal inserts is highly demanding. The choice of material should not only consider the formability of metal inserts. It is also necessary to consider the impact and corrosion of high speed and high-pressure plastic melt on the metal inserts during the injection process.
In addition, the thickness of metal inserts is also an important factor affecting injection molding.
As the thickness of metal inserts increases, the stiffness increases, and the resistance to plastic melt shrinkage and deformation is enhanced.
When the thickness increases, the bond strength between plastic melt and metal will be affected.
At present, the most commonly used metal inserts are copper, copper, aluminum, aluminum, and stainless steel.

(3) The choice of plastic material should consider the working condition of the final molded plastic. Plastic parts with metal inserts are widely used in the field of electronic automobile, so higher requirements are put forward for the strength and heat resistance of plastic parts materials. At present, PBT+GF PEEK PC ABS and other plastic materials are widely used.
4)The quality of the molded parts is difficult to guarantee, the cooling rate and linear thermal expansion coefficient of metal inserts are different from that of plastics, and the forming plastics are easy to form fusion connection mark during injection molding, which will aggravate the cracking and warping deformation of the forming plastics during the cooling process, and affect the qualified rate of the final forming plastics

10. What are the general defects of insert injection molding of metal inserts?

The general defects of insert injection molding of metal inserts are as below.
(1) The bonding strength between the metal insert and plastic parts is low, this may be because the metal inserts have not warmed up.
(2) The finished parts are liable to warp and deform.
(3) The Metal inserts are vulnerable to damage. So in the first step of insert Injection molding, Place the metal parts in the fixed mold cavity and fix the positioning, be sure to place metal inserts carefully.
(4) Dimensional accuracy is difficult to control.
(5) The finished parts easy to appear clip water grain and so on.

11.What’s the difference between Insert Molding VS Over molding?

The difference between Insert Molding VS Over molding is as below:
The over-molding mold is a mold that wraps a product and then cools it down naturally and puts it into another mold for re-injection so that the secondary parts can be wrapped together.
The insert mold is a mold that puts the inserts directly into the mold at the beginning of the molding process.
The over-molding needs two times or more injection molding. But the insert molding just needs one-time injection molding. Compared with the over Molding, the insert molding is able to simplify the production process and shorten the injection molding cycle.

 

12.What industry Insert molding is mainly used in?

The industries that the Insert molding mainly use in are as below:
The insert molding could adopt in various Industries, Such as the toy industry, home furnishing industry, automobile industry, home appliance industry, and so on.
Insert Moulding is a very widely used process. The Kemal team was familiar with the technical details of the Insert Molding.
Insert molding is a molding process in which plastic is injected after a prepared different material, and the insert is loaded into the mold.
Besides that, the fused plastic is perfectly joined and cured together with the insert.
The insert molding process can be used for the production of integrated products.

 

13.Why the Insert molding process is used for the complex integrated metal and plastic product?

Because the plastic material’s formability and bendability can complement each other with the metal’s rigidity, strength, and heat resistance, the insert molding process can be made firmly into complex metal-plastic integrated products.
Insert molding is a very widely used process. The Kemal team was familiar with the technical details of the Insert Molding for 24 years.
Insert molding is a molding process in which plastic is injected after a prepared different material, and the insert is loaded into the mold.
Besides that, the fused plastic is perfectly joined and cured together with the insert.
The insert molding process can be used for the production of integrated products

14.Why the insert molding process generally used in the production of electrical products?

Because the insert molding process takes advantage of the insulation of plastic materials and the electrical conductivity of metals, the properties of the two materials are perfectly combined.
The finished parts can meet the basic functions of electrical products: conductivity and insulation.
Insert Molding is a very widely used process. The Kemal team was familiar with the technical details of the Insert Molding.
Insert molding is a molding process in which plastic is injected after a prepared different material, and the insert is loaded into the mold.
Besides that, the fused plastic is perfectly joined and cured together with the insert.
The insert molding process can be used for the production of integrated products.

 

15.What factors should we consider before Insert molds design for Products prone to damage, such as Glass, coil, electrical parts?

The factors that we should consider before Insert molds design for Products prone to damage are as below:
Before the mold design, we should consider the selection of appropriate resin and molding conditions for Products prone to damage, such as Glass, coil, electrical parts.
And we need to considerate to times of insert molding, also we need to considerate the fusion of plastic with Glass, coil, electrical parts. the Glass, coil, electrical parts are very difficult to fix. We need to reserve some space in the mold for the insert.
Finally, we need to consider the appropriate mold dimensional tolerances and mold temperature, as well as the design of the gate cross-sectional area.

 

16.What do we do if we want to seal the insert completely into the plastics materials?

If we want to seal the insert completely into the plastics materials. In the early stage of mold design, we should fully consider the structure of mold design and choose the appropriate mold structure.
Also, we should consider the times of insert molding. Besides that, we should consider that Choose the right mold size and tolerance, choose the right plastic shrinkage rate, choose the right plastic, choose the right product wall thickness.
Sometimes it is necessary to preheat the insert parts and glue the surrounding of the insert twice or more times.

17.How can insert molding to achieve automatic production?

If we want to realize automatic production, we need the combination of vertical injection molding machines and manipulator assembly.
The insert molding machine and assembly must both meet certain precision requirements.
When the Insert molding is automated, it greatly reduces the production cycle, improves the production efficiency, reduces the processing cost, and reduce the failure molding rate.

18.Why should metal inserts be positioned when they are molded?

If the metal insert is not positioned during molding, or the positioning of the metal insert is unstable when filling with glue, the metal parts will shift.

19.Why is insert molding widely used in the production of automotive plastic products?

Metal insert injection molding technology combines the advantages of plastic and metal,
On the one hand, metal inserts can effectively improve the local mechanical strength and wear resistance of products.
The forming part is used as the structural bearing part for the automobile body and so on.
It not only meets the requirements of mechanical properties but also conforms to the development trend of automobile lightweight.
On the other hand, the good conductive property of the metal insert and the good insulation property of the plastic are combined, so that the finished part can be applied in the electronic circuit and other aspects.

20. In the plastics insert molding, How can we enhance the bonding strength between metal inserts and plastic inserts?

Reduce the influence of the external environment on the bonding strength of metal inserts and plastic melts.
We should pay attention to control mold temperature and humidity in the production environment.
Consider whether metal inserts need to be warmed up.

 

21.What are the special considerations for Insert Injection Molding?

(1) Insert Molds design: good insert mold design and structure is crucial to the smooth production of the insert and component which requires careful thinking and consideration at the early stage to avoid problems at the later stage.
(2) Sufficient material: No matter what’s kind of material you use, there must be sufficient material to support the insert, because the thin walls can cause the insert to fall away from the rest of the part. It’s necessary to make sure that there is enough plastic material to properly place the inserts.
(3) Insert Pressure: It’s a very important factor, the insert needs to withstand the pressure because the molding process will create a lot of pressure, make sure the inserts can handle the pressure without cracking or deforming is crucial.
(4) Insert temperature: The inserts need to be safely exposed to the temperature required to melt the plastic injection material without deforming the insert.
If the insert cannot withstand the temperature required for the melted plastic material. It will need to find a different plastic material with a higher melting point in order to use it safely.

22.Why Kemal was chosen to produce the insert injection molding mold?

(1) Kemal has studied the defects of insert injection molding for many years, and we can well solve the problem of weak bonding between metal inserts and plastic parts in insert injection molding.

(2) Kemal has produced automobile products that require insert molding process for many years, such as automobile electronic dashboards and other automobile products with metal inserts.

(3) Kemal Team has rich experience in insert injection molding of embedded parts and can respond to customer questions within 24 hours.

(4)Kemal Team can fly to your city and solve the problem on the spot when it is necessary.