Insert molding is a manufacturing process used to integrate metal or plastic components into a single mold to create a finished product with complex structures. This process involves placing an insert (which could be a metal part, threaded rod, or another plastic component) into a mold, and then injects molten plastic around it, thus embedding the insert securely within the plastic part.

1. Design: The process starts with designing both the plastic part and the insert, ensuring they fit together precisely. This involves CAD modeling and often prototype development.
2. Insert Placement: The insert (pre-manufactured component) is carefully placed into the injection molding tool. It must be positioned correctly to ensure the molten plastic flows around it seamlessly.
3. Mold Clamping: Once the insert is in place, the mold is closed and clamped tightly to ensure no leakage occurs during the injection process.
4. Injection: Molten plastic is then injected into the mold cavity, surrounding the insert. The high pressure ensures that the plastic fills all crevices and gaps around the insert.
5. Cooling: After injection, the mold and the part are cooled to allow the plastic to solidify. Cooling channels within the mold help expedite this process.
6. Ejection: Once the part has sufficiently cooled and solidified, the mold opens, and the finished part with the embedded insert is ejected.
7. Inspection and Finishing: The ejected part is inspected for quality, and any necessary finishing operations (trimming, cleaning) are performed.

• Durability and Strength: Insert molding provides a durable and strong bond between the plastic and the embedded insert, enhancing the product's structural integrity.
• Reduction in Assembly: It minimizes the need for secondary assembly operations, reducing labor and production costs.
• Design Flexibility: Allows for the creation of complex and intricate parts that combine different materials.

• Components with threaded inserts.

• Electrical components such as connectors and switches.

• Medical devices.

• Automotive parts with metal reinforcement.