Insert molding service
Insert molding involves molding plastic around a non-plastic component to create a finished part. With 22 years of insert molding experience, Fuming has the equipment and expertise to address all custom insert molding requirements and solutions. Our capabilities are ideally suited for custom medium and low-volume components across numerous industries, including medical and industrial applications.
Fuming focuses on insert molding services
Which help reduce assembly and labor expenses while enhancing design adaptability and component functionality. Our vertical injection molding machines, equipped with a turntable, enable overmolding and encapsulation of inserts for circuitry, fastening, and connections. Typical products from this process include sensors, switches, connectors, and actuators. Fuming’s insert molding capabilities encompass: manual and fully automated operations, additional secondary molding processes, blanking operations, and comprehensive 100% pressure resistance and continuity testing. We offer engineering, custom injection molding, and contract manufacturing services using our advanced technology. Our clients present demanding applications that require insert molding, ideally handled by our expert engineers.
Insert molding online quote
Fuming provides insert mold services as part of its injection molding capabilities. To receive a complimentary insert molding design review and quote, simply upload your CAD files here. Our skilled injection molding team will respond within 24 hours. If injection molding isn’t the ideal solution for your project, consider exploring urethane casting or 3D printing as alternatives.
Benefits of Insert Molding
Stronger Parts
Complex components are produced through a single-shot process that yields stronger parts compared to alternative molding techniques.
Durable and Flexible Solutions
By eliminating fastener wear and tear, insert molding extends the overall lifespan of the component.
Cost and Production Time Savings
By implementing an insert molding process or component, secondary operations and their associated parts can be eliminated.
Affordable Tooling
Molds engineered for vertical operation typically cost less than those designed for horizontal use, and the minimized setup time makes short production runs economically viable.
FUMING Insert Molding Services
Cable Overmolds (Learn About Custom Cable Assembly Manufacturing)
By encapsulating wire harnesses in plastic, cables gain enhanced durability, improved ingress protection, and a more polished appearance. Insert molding can also extend cable flex life through the addition of an overmolded bend relief.
Soft Touch Overmolds for Grips, Seals, and Aesthetics
Custom insert molding enhances both the aesthetic and ergonomic design of products. Applications include grips for improved ergonomic comfort, replacing traditional o-rings and gaskets with soft touch overmolded features, and adding a soft-touch skin to your design for enhanced aesthetics and tactile feel.
Custom Connectors (Discover Custom Connector Manufacturing)
Insert molding is utilized to encase electrical contacts within a durable, rigid plastic. These bespoke connectors can be engineered to precisely match your application's requirements.
Fastener Threads and Studs
Custom insert molding is used to embed standard female threaded inserts or male studs, enhancing overall product durability.
Design considerations
Fuming injection molding services enable you to manufacture parts that meet a variety of functional needs. Unlock the potential of your insert molding project by considering the following injection molding design factors.
Insert molding general process information
| Maximum part size | 800 x 800 x 400 mm 31.5 x 31.5 x 15.7 in |
| Minimum part size | 1 x 1 x 1 mm 0.04 x 0.04 x 0.04 in |
| Tolerance | Best achievable tolerance: ±0.001″ (0.025mm) Standard: ±0.005″ (0.127mm) For larger part tolerances please contact a FUMING engineer |
| Lead time | As low as 2 weeks for T1 samples After T1 sample approval, lead time for < 10,000 parts is as low as 1 week |
| Tool validation | Standard process is to produce a small set of T1 samples for approval before initiating full production |
| Maximum press size | 1600T |
| Minimum order size | 100 parts and $5000 |
| Set-up fee | $500 per mold per order (applies to sample runs after initial T1 samples or engineering changes) |
Insert molding tooling information
| Rapid tooling | Molds with steel cavity and core, providing a shot life of 5,000 to 10,000 cycles. Typically machined within two weeks. |
| Production tooling | Production-grade steel tooling with a shot life of up to one million cycles. Capable of integrating side-pulls or cam-action mechanisms. Standard lead time is three weeks. |
| Multi-cavity or family molds | Multi-cavity tools, either with identical cavities or configured for a family of parts. This design increases output per cycle, effectively lowering the unit cost per part. |
| Inserts | Interchangeable inserts placed within the mold, with material molded around them to enhance the longevity of critical features. This method also permits components like helicoils to be integrated directly into your molded design. |
| Most common materials | Other supported materials | Additives and fiber |
|---|---|---|
| Acrylonitrile Butadiene Styrene (ABS) | Nylon (PA 6, PA66, PA12) | UV absorbers |
| Polyethylene (PE) | Polycarbonate/Acrylonitrile Butadiene Styrene (PC/ABS) | Flame retardants |
| Polypropylene (PP) | Polyurethane (PU) | Plasticizers |
| Polycarbonate (PC) | Polymethyl Methacrylate (PMMA/Acrylic) | Colorants |
| High Density Polyethylene (HDPE) | Glass fibers | |
| Low Density Polyethylene (LDPE) | ||
| Polystyrene (PS) | ||
| PEEK | ||
| POM (Acetal/Delrin) | ||
| Polyethylene Terephthalate (PET) | ||
| Thermoplastic Elastomer (TPE) | ||
| Thermoplastic Vulcanizate (TPV) | ||
| Polyetherimide (PEI) | ||
| Polysulfone (PSU) | ||
| Inquire for additional options |
Insert materials
| Metal | Plastic |
|---|---|
| Brass | Polypropylene (PP) |
| Stainless steel | Polyamide (Nylon) |
| Aluminum 6061 | Acrylonitrile Butadiene Styrene (ABS) |
| Aluminum 7075 |
Injection molding finishing and post-processing
We offer a variety of injection molding finishing and post-processing techniques for insert molded parts.
Insert molding colors, finishing, post-processing
| Colors | Finishing and post-processing options |
|---|---|
| Pantone color matching | Standard SPI finishes (A2-D3) |
| RAL color matching | Mold-tech textures also available |
| Pad printing | |
| Inserts (e.g. heat stake inserts) | |
| Light assembly | |
| Protective packaging / film |
Custom Insert Molding Gallery
Explore examples of our custom plastic injection molding, designed for specialized filtration applications.
Examples of Insert Molding Applications
Insert molding is well-suited for numerous applications across diverse industries. Provided below is an example of insert molding manufactured by Fuming.