Expert Insert Molding

Insert molding is a versatile manufacturing technique that allows for the seamless integration of plastic and metal components into a single, high-performance part. At Ichiplas, we've honed our expertise in this specialized process, delivering customized solutions for a wide range of industries.

What is Insert Molding?

Insert molding involves injecting plastic around a pre-placed insert, which can be made from a variety of materials, including plastic or metal. This process creates a strong, permanent bond between the materials, resulting in a single, integrated part.

The insert can range from a simple threaded insert or metal rod to more complex components like batteries, motors, or electronics. By combining these elements during the molding process, insert molding eliminates the need for secondary assembly steps, streamlining production and enhancing the overall product design.

Insert Molding

The Ichiplas Advantage

Competitive Pricing

The streamlined insert molding process at Ichiplas delivers numerous efficiency benefits:

Reduced waste and scrap through precise part tolerances
Improved production yields and lower reject rates
Simplified supply chain management and logistics
Faster time-to-market for new product introductions

Enhanced Durability

The strong bond created between the plastic and insert material through the molding process results in:

Superior impact resistance
Extended product lifespan
Reduced risk of component separation

Improved Functional Integration

Embedding inserts during the molding process to seamlessly integrate various functional components, such as:

Electronic sensors and circuitry
Mechanical fasteners and connectors
Reinforcing structures and supports
Aesthetic and branding elements

Used across various industries

Applications of Insert Molding

By combining the unique properties of plastics and metals, insert molding enables the production of parts with improved functionality, aesthetics, and performance.

Insert molding is widely used across various industries to create products that require the integration of different materials, such as:

Household appliances: Examples: handles, controls
Automotive components: Examples: pedals, gear shifters
Medical devices: Examples: surgical instruments, drug delivery systems
Consumer electronics: Examples: housings, connectors
Industrial equipment: Examples: power tool components, machinery parts

Our Insert Molding Process

At Ichiplas, we follow a rigorous process to ensure the highest quality insert molded parts:

Design Consultation and Material Selection: Collaborate on design specifics and select ideal materials for optimal performance.
Prototyping and Testing: Create and rigorously test prototypes to verify design and material compatibility.
Mold Design and Fabrication: Design and fabricate custom molds using advanced CAD/CAM and CNC technologies.
Insert Preparation and Placement: Precisely prepare and position inserts within the mold for secure integration.
Injection Molding: Inject plastic around the pre-placed insert, ensuring a strong, permanent bond.
Quality Control and Testing: Conduct comprehensive quality checks, including dimensional, strength, and functional testing.
Final Assembly and Packaging: Assemble additional components and package products for safe, secure shipping.

Project Examples

Our showcase exemplifies the consistent excellence that defines Ichiplas. From the smallest parts to complex assemblies, we maintain the same high standards across all our products, ensuring you receive nothing short of the best, every single time.

Overmolded Fabric Filter

A highly complex double overmolded vacuum filter with fabric substrate.

Process: Double overmolding on fabric substrate, insert molding with magnet

Materials: Two types of Thermoplastic Elastomer (TPE)

Dimensions: Outer diameter: 8cm, Height: 10cm

Applications: High-performance vacuum cleaners, industrial filtration systems

Advantages: Enhanced filtration efficiency, magnetic quick-release capability

Key Features:

Complex multi-material design
Integrated magnet for secure attachment
Durable fabric substrate for efficient filtration

A highly complex double overmolded vacuum filter with fabric substrate.