Insert molding and overmolding are two different processes that are used to create similar but distinct products. In insert molding, a thermoplastic is applied to an elastomer or rubber substrate and then suspended within a mold. The process is useful for creating intricate shapes and complicated dimensions. Often, the substrate is an additional material that is necessary to complete the design. This can include a wire, a computerized part, or other materials.
There are several advantages to overmolding over insert molding. Overmolded parts have a smooth surface and are stronger than parts made of two separate plastic components. They also eliminate glue, which can be a failure mode. Plus, they reduce total assembly cost and part to part variability.
Insert molding can be used to produce plastic parts for a wide range of industries. It is commonly used in the medical industry. It is also a common process for manufacturing automotive parts. Many household items undergo this process, such as step stools and patio chairs. It is also used for the production of solid materials with multiple colors.
In addition to reducing assemblage costs, insert molding can increase productivity. It is more expensive than injection molding, but it can be beneficial to a variety of industries. While both processes are beneficial, there are a few significant disadvantages to both methods. One of the most significant drawbacks of insert molding is the need for a high degree of precision. Moreover, the materials used for insert molding should be compatible with each other.
Overmolding involves the use of two shots of materials, while insert molding uses a single shot of molten plastic. Insert molding is quicker than overmolding, but if the insert is made from metal, the production time can be prolonged. If the metal insert is custom, the process will require a separate purchase.
Overmolding is more complex and requires multiple shots. Insert molding is more cost-effective than overmolding and is more versatile. For example, it can be used for gears that must fit onto a metal shaft. It can also be used for metal guide pins with plastic retainers. Insert molding opens up design options, reduces the manufacturing cost, and improves quality.
In addition to reducing manufacturing costs, overmolding also extends the life of the product by adding extra protection. Overmolded parts can provide a range of benefits, including sealing, sound absorption, and vibration dampening. They can also increase safety and ergonomics.
Overmolding begins with a base substrate, such as plastic or metal. The plastic substrate is molded in the same production cycle as the overmolding material, making it more cost-efficient to produce the part in one piece. The elastomer adheres to the warm substrate more easily.
Insert molding is similar to overmolding, but insert molding involves the addition of metal inserts to the product. The metal inserts are inserted into a tool before the plastic is molded. The plastic material then flows around the metal insert, encapsulating it, and integrating it into the larger injection molded part.
