Insert Molding

Insert Molding

Asia Billion can help you to develop your insert molding plastic project. insert molding widely use for electronic enclosure , automotive plastic housing,appliance covers and so on. this project come from our Germany automotive injection molding customer. this part is for engine and power system. the material for the molding plastic is PA66+GF33%. it can load the Max temperature up to 260 ℃.

Product Details

Asia Billion can help you to develop your insert molding plastic project.  insert molding widely use for electronic enclosure , automotive plastic housing,appliance covers  and so on.   this project come from our Germany automotive injection molding customer. this part is for engine and power system. the material for the molding plastic is PA66+GF33%. it can load the Max temperature up to 260 ℃. 

 

Production details:  

Type:

insert molding

Core surface finish:

normal polish

Production Material:

PA66 +GF33

Cavity surface finish:

MATT finishing

No of Cavities:

1x 2

Injection System

Cold Runner

Core Material:

1.2343 with heat treatment

Type of gating:

Sub gate

Cavity Material:

1.2343 with heat treatment

Cycle time:

50 s

Slider material:

N/A

Lead time for T1

25 days

Cooling:

Hot oil

Mold life:

1 000 000

Place of Origin

China

Mold cost:

USD 10000


Product Characters

1. automotive plastic injection molding plus insert molding

2. import brass screw from customer in Europe

3. PA66 engineering plastic injection molding with Max 6.0 mm thick wall

4. Warpage control for the assembly area

5. release of stress under 180 ℃ for 30 minutes for the samples and mass production


Please note that this information is just for reference and don’t copy or use to others purposely.   



Asia Billion Overview:

Asia Billion Injection mould tooling plant overview



Asia Billion Production Quality Control and Certifications:

plastic injection molding quality control


Asia Billion Mold and Production Storage:

Asia Billion Mould and production storage


Application of metal insert technology in injection molding


   Metal inserts in the mold, we usually call insert molding. This technology has been very mature after many years of development, and Asia Billion also has a lot of projects using this technology. This solution combines the excellent plastic easy shape with the strength of metal inserts, which greatly expands the application area of our injection molded parts.


   However, many companies or product design engineers who are not very familiar with the insert molding field have encountered various problems. For example, yesterday our Asia Billion's military products customers purchased injection molded housing from other companies using a heat stake process to implant the nuts, but the scrap rate is high, and the dimensional accuracy is not enough for sealing. The most terrible thing is to assemble and play products. At the high and low temperature test, the boss column where the nut located is basically cracked or broken,  the function is seriously affected at present. it cause big losing for total project and time.


  So if we determine the product using the insert molding solution, we need to make adjustments from the product design. Nuts and metal inserts usually need to be positioned if they need to be placed in the mold. it need bigger and stronger than the normal self-trapping screw. The positioning includes the position and height. Usually, the nut needs to be inserted into the inner hole of the nut by the inserting pin, and the height is made of a certain surface of the mold steel as the reference surface. It should be emphasized here that the inner insert pin must have a precise fit with the nut. It should not be too loose or too tight. If the too loose nut is subjected to the pressure of injection molding during the injection molding process, it may cause the gap to enter the plastic or have flash. Cause irreparable waste. If too tight, it can be very difficult to put in the nut, and it is very easy to damage the nut or mold part during the production process. We usually reserve a gap of 0.02-0.03mm between the nut and the insert, which is a very reasonable assembly tolerance.


   In addition to the above cracking and breaking problems, we will elaborate on this. Because the customer's boss length to diameter ratio exceeds 3, and the high speed injection molding does reduce the protection of the ribs, and the way the customer uses the plastic parts after injection molding, the product has a large internal stress after the nut is implanted. Therefore, when the final product was asked for the test, the product eventually cracked. The solution given by Asia Billion here is to change Insert molding, while increasing the plastic position thickness and rib height of the boss column. This will perfectly solve the problems encountered at present, the customer also gave us a high evaluation, and verbally agree to the next project order to us.


   In addition, when we do insert molding, we need to pay attention to the customer's requirements for product torque, etc. must make special structures on the nut, such as steps and patterns, and the lack of torque. At the same time, we must pay attention to the huge difference between metal inserts and plastic shrinkage. There are other problems in the way such as crack, internal stress.


If you have a different understanding of insert molding, or if you are having trouble with the production process, or if you need to find a reliable long-term supplier of insert molding, please feel free to contact Asia Billion.

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