Insert injection molding, also known as plastic insert molding, is the process of forming plastic around a non-plastic insert, which can be as simple as a metal rod or as complicated as a battery. When plastic is molded onto the insert, the two components augment each other, resulting in a more reliable final product that offers advantages from both materials. Usually, engineering plastics are used for insert injection molding because of their superior characteristics, such as their resistance to damage, their tensile strength, and their low weight.
At PDI Molding, we provide in-depth, comprehensive insert injection molding services and work with various plastic grades, including both consumer and engineering grade plastics. We also operate 21 different molding machines, including robotic sprue pickers, automated conveyors, coordinate-measuring machines (CMMs), and a vertical press that uses a rotary table and engineering-grade plastics. Our advanced setup and over 40 years of experience allow us to handle even the most complicated assignments with reliability and precision.
Vertical Presses with Rotary Tables
Compared to horizontal molding machines, vertical presses are usually more versatile and efficient. At PDI Molding, we pair our vertical press with a rotary table, which allows us to make the mold and insert the part at the same time. A rotary table holds two B halves of a mold so the operator is able to add inserts to one B half while the second B half is molding product and mating with the A half. Vertical presses that use rotary tables are precise and methodical, making them ideal for processing complex inserts via plastic insert molding.
Engineering-Grade Plastics
Commodity plastics can be used in many different applications. However, they are relatively weak, unsuitable for high temperatures, and susceptible to chemicals.
Engineering-grade plastics, on the other hand, have better mechanical and thermal properties than commodity plastics. They are durable, fire-retardant, and chemical-resistant, making them perfect for specialty applications such as those found in the medical and safety industries.
Examples of engineering grade plastics available with insert injection molding include:
- Glass-filled nylon
- Polyether ether ketone (PEEK)
- Acrylonitrile butadiene styrene (ABS)
- Polycarbonate
- Ryton
