Comparing Insert Mold and Traditional Mold

The industrial zone is full of techniques for molding different materials such that they fit with their specifications. The traditional way of molding was a revival for the mold-making industry. But now we have come way forward and are implementing as well as inventing new ways of molding.

The idea behind the technique of insert mold is to allow alterations and additions in the preexisting molded parts. Using the insert mold, a metal molded part inserts in a new mold. Then the plastic over-molding facilitates the partial or full coverage of the metal part.

Now, this is thermoplastic encasing of the metal component which is actually the mating of two parts to become the part of the bigger picture eventually.  Hence, the name insert mold comes into existence. More people are making the transition of using insert molding. This way they can develop a big product in parts, making the final assembly easier.

All you need to know about Insert Mold

The insert molding is the encapsulation of already molded parts in a thermoplastic. The ideal way of doing it is to give shape to molten plastic that is desirable in the final product. The traditional way of molding has many limitations therefore the insert mold technique is becoming an alternate solution.

Any particular project demands using different molds thus, the insert molding allows the molding of different parts despite their different characteristics and physical properties. Unlike insert molding, traditional molding demands to melt the plastic until they soften. This takes place at high temperatures.

Once the material reaches the desired physical state, it needs to fill the molds that have different shapes to achieve the final look. Consequently, it is a painstakingly long process and requires very precise steps. Although insert molding works on the basic principles of molding, it is still a laid-back technique with great results statistics.

Preferring insert mold over Traditional Mold

The insert molding process is viable as it makes use of melted resins and encloses the metal component. This process allows the plastic to encase the main metal body completely. Thus, the plastic outer body has no flaws with evenness in thickness. It even conceals the metal for any deformities due to earlier processing.

The varieties of applications associate with insert molding are countless. It even allows simple applications as well as complex ones. Majorly the reason to prefer insert mold over traditional mold is because of its continuity in production. By continuity, we mean that the plastic parts are in the form of a shield rather than add-on accessories.  Using mechanical bonding in insert molds, the plastic gloves the metal part just in a natural formation.

CNC Machining

CNC machining is the technique that allows this combination. It is good for providing soft grips and superior design. This is a sure short method of attaining sturdy structural designs that exude power and strength. One more reason to prefer insert molds over traditional mold is because of its cheaper production costs and further facilitates three-dimensional sculpting.

A traditional molding process is way more intense and involves too many steps. When using this process, the product has to go through injection, fusion, bonding, connectors, thread inserts, and fasteners. In short, there is too much going on. Unlike traditional molding, insert molding is precise and to the point. Moreover, the final product is much more consistent and sturdier. This gives the manufacturers a way better choice when they require molding.

Tip-Top Molds is all the facilities regarding molding. They provide services for all the molding processes under one roof.

Benefits of the using Insert molding process

As discussed earlier, the insert molding process is useful when we want parts that are strong and sturdy. It is by far the most reliable process for developing powerful tools. Moreover, it is very effective and has a high rate of efficacy when making molds for manufacturing processes. It makes up a consistent platform for making molds.

There are some major benefits of using the insert molding process for making molds.

Hand-Picked Material 

First of all, it lets the manufacturer choose the materials they want in the design mold. These materials are hand-picked due to their specialties. This means that the final product is compatible even before it comes into existence. Another reason for choosing specific materials is that they suit the production type whether it is marketable or domestic.

Affordable 

Moving on to the next benefit, insert molding is a cheap method for molding because of its cost-efficiency. The reason it is cost-effective majorly relies on the fact that it only consists of one step. This remarkably reduces the costs that might accumulate due to assembling and labor-intensive tasks in traditional molding processes.

Compatibility 

One more benefit of using insert molding is that all of the parts involved in the technique are already compatible. This means that there is no chance of failure or mishaps in alignment with the outcome. It substantially reduces the number of risks. The calculated results urge more manufacturers to invest in insert molding rather than other molding processes.

It even facilitates flexible design opportunities and allows the user to create unique components due to zero risks. The entire outcome is basically a single and even sheet of plastic thus the finishing is perfect. Some common examples include industrial tools, home-based utensils, chemical apparatus, and much more. It helps in catering to a vast variety of fields be it technical or domestic in nature. 

Summary

Finally, it is beneficial to conclude that the technique of insert molding is far more superior to any other technique used for molding. This is a state-of-the-art latest technology that manufacturers prefer over any other technique.

The reason it has been around for some time now is because of its long list of benefits that keep on increasing day by day. Moreover, it gives a chance to the manufacturers to experiment with different kinds of materials with zero risk factors. It emphasizes greater outcomes and lesser input whether it is related to labor, cost, or efficiency.  

A Guide to Overmolds Prototyping

In order to understand overmolds prototyping, it is better to get to know overmolds first. The process of overmolding involves the creation of one component. This single-component comes into existence using two or more than two materials that are unlike each other.

The first material for overmolds is a substrate that has a partial or full covering by the succeeding material in the manufacturing. This covering refers to the overmolding. In the manufacturing process, substrate and overmolding material play a major role in attaining the final product.

You can also refer overmolds as a molding process using an injection in combining different materials for making the wire and connector into a single component. Basically, one material overpowers the other one for this combination to exist. This article elaborates on the basics of overmolds for a comprehensive understanding.

The Use of Substrates in Overmolds Prototyping

As mentioned earlier overmolding prototype manufacturing includes substrates and overmolding materials. The first object or material inserted in overmolding is the substrate. In manufacturing terms, a substrate can be any material.

For example, it can be a metal component that came into existence using machined manufacturing or it can be in the form of a molded part consisting of plastic. It can even be a thread particle or a metal connector like screws and more.

The strategy behind making prototyping is to work on this very part known as the substrate. This very substrate will become a continuation in chemical bonding for goal attainment. It allows mechanical interlocking of different types of materials too.

Substrate, being the underlying layer serves as a platform. This becomes a solid foundation for further works required in overmolds prototyping. Moreover, this can be the beginning of a better way of molding objects as required.

The Use of Overmolding Material in Overmolds Prototyping

The next step of overmolds prototyping involves using an overmolding material. In most cases, the overmold material can be plastic. If it is plastic, then it comes in the shape of a capsule. For initiating the overmolds prototyping, it is important to add certain colors and fillers.

Sometimes it may need agents to create foam and make an even solution of the overmold material. The next step is to heat the capsulated overmold material until it reaches its molten point. Next, using an injection fill up the mold. This all takes place when the material is in the form of a liquid. There are some limits when using an overmolding material.

The most suitable material for the prototyping process is plastic. It is compatible with numerous amounts of materials. Otherwise, if you are using other materials then there might be some issues when covering the substrate.

Compatibility charts are often available with manufacturers that are into overmolding prototyping. It depends on the manufacturer and their experience with different materials. We, Tip-Top Molds (https://www.tiptopmolds.com) have vast experience in testing different types of material in overmold prototyping. You may select us due to our exceptional knowledge in combining materials for overmolds prototyping.

The Applications of Overmolds Prototyping

The industrial field requires many manufacturing procedures for their productions. Furthermore, overmolds prototyping is one of the many techniques used in the manufacturing of different components, for machinery or construction purposes.

The reason many companies are using overmolding prototyping is its ability in manufacturing different projects. Even if it does not produce the final product, it helps in producing the parts that are integral for the out-coming product.

Therefore, it has multiple applications compatibility in producing different types of materials. Some of the common household items come into existence after going through overmolding prototyping. This includes hand grips for our everyday appliances and objects like a toothbrush or a razor. The following are some more applications of overmolding prototyping.

Plastic over Plastic Overmolds Prototyping

As the name suggests, this kind of prototyping involves overmolding of plastic over and other plastic. A substrate is usually a solid form of plastic that needs molding. The next step is to surround the first plastic with another plastic.

The second plastic is in molten form so that it covers the substrate partially or completely as is the requirement by the manufacturer. Since the specifications of the final product depend on the client, the plastics used can differ in color, size, and other qualities.

Rubber over Plastic Overmolds Prototyping

Another application of overmolds prototyping is when making use of rubber over plastics. The first element or substrate is a slid kind of plastic. As usual, the substrate is in the molded form. Further, this plastic needs the covering of soft rubber or Thermoplastic elastomers.

We can experience this kind of coverage in products/devices with a gripping area that is soft. The soft area covers a solid part for easing the grip to facilitate proper handling.

Plastic over Metal Overmolds Prototyping

The next kind of prototyping involves using plastic and metal. In this case, the substrate is a metal that requires machining for its casting and formation. The next step is to insert the metal substrate into an injection. Over here, the injection acts as a tool for molding.

Then the manufacturers make use of plastic in molten form for giving coverage to the metal part. Once more, the metal is covered with plastic to provide a secure area for gripping. You can often locate this kind of prototype overmolding in screwdrivers, and more of these handy tools.

Summary

The technique of using overmold prototyping is becoming more and more common because of its cost variety of applications. Although it has some of its limitations, it is still a viable procedure for a variety of manufacturers. It allows using different kinds of materials. Moreover, you can even use different colored pigments and parts in achieving the desired result.

It is also an economical method for making physically and seamlessly bonded products. This allows the manufacturers to be more creative in productivity. It even adds flexibility along with a soft grip to different products.

 

Overmold Supplier

Overmolding is the process of injection molding that combines different materials into one product or part. It usually includes a plastic-substrate, thin part overlaid with the pliable, thin, rubber-like TPE (thermoplastic elastomer)exterior layer and other materials utilizing two-shot/multiple-shot molding or insert molding (single-shot) technique. Overmolding has become a popular technique for manufacturers for its positive impact on products. This technique can prove beneficial for your next project for the many advantages that it provides. However, it holds immense importance to find the right overmold supplier for your project.

In this article, we will show you the impact of overmolding on products. But before that, let us show you how to find the most reliable supplier for your specific project.

Tips to Identify the Right Overmold Supplier

Hiring an overmolding supplier is a rational decision because it will bring fruitful results to your business. But, there are certain considerations that you must keep in mind before hiring any overmold supplier.

Remember that choosing the right supplier holds the key importance in setting a perfect business foundation to ensure success in the long run. The supplier you choose will have a significant impact on the growth of your business.

Therefore, it is necessary to hire a highly reliable supplier for your project. Here are some useful tips that can help you choose the right overmold supplier.

1. Never Compromise over the Supplier’s Reputation

Before you choose a supplier, you must know their reputation in the industry. To measure the reputation of a potential supplier, you can take a look at various factors.

Those factors include organizational ethics, management and leadership, financial performance, quality of services and products, reliability, customer service, and social responsibility. It also includes the digital reputation of the company.

Remember that the digital reputation of a company significantly influences the trust of consumers. Make sure that the supplier you hire is known for a positive reputation.

2. Understand the Possible Consequences of Low-Priced Suppliers in Long Run

Companies usually lower their overall experience with time whenever they find an opportunity. For instance, they may lower the production cost by choosing components manufacturers with low-cost material creation.

Low price for increased production rate is tempting, but you must be cautious when selecting a manufacturer just to minimize the invoice amount.

3. Understand the Difference Between Value and Price

The terms ‘value’ and ‘price’ are not interchangeable. There is a significant difference between the two terms. Value is a supposed benefit, while the price is random. Even when you want to reduce the expenses to the maximum, you must not risk any reduction in the product quality.

Remember that you are not just paying for the part cost, but also the manufacturer’s service. You will receive an overall value from the cost which covers reliability, manufacturer’s service, and product quality. Therefore, never hire an overmold supplier just because they have extremely low rates.

4. Check the Parts Quality before Committing

Product quality must be your priority. Remember that high-quality products bring exceptional advantages to your company by fulfilling industry standards and customer expectations.

It will help you build a long-lasting relationship with customers if you consistently deliver quality products. Therefore, it is critical to ensure that you build your product using top-quality parts.

Before you hire any overmolding supplier, you can check the quality of their parts. You should ask for product samples, especially if you are prototyping new products.

It is important to ask maximum questions to the supplier. Whatever comes to your mind, you should discuss it with them. For instance, you should ask them if they need minimum orders.

It will help you know the lowest numbers of parts they can manufacture for you. You should also ask them about their production pricing. Ask them if they can provide sample pricing. Doing this will also help you check the quality of their product before you order in bulk quantity. It is also essential to know the supplier’s turnaround time.

Impact of Overmolding on Products

Overmolding has become significantly critical for many products. For instance, overmolding helps in enhancing the ‘feel’ or grip of a product by adding a soft-touch exterior. It also helps in ensuring a great visual appearance to attract consumers. Moreover, overmolding reduces vibration and shock, offers electrical insulation, dampens sound, and enhances UV/chemical resistance to improve product longevity.

The following advantages will show you the impact of overmolding on products and profits by hiring an overmold supplier:

1. Improved Product Performance

The primary reason behind designing and manufacturing a part or product with overmolding is to enhance the performance of the product. A thermoplastic elastomer is a perfect material to create a non-slip, soft grip for various products that require tactile feedback is critical.

One common instance of this is the medical products, like surgical instruments. Additionally, thermoplastic elastomer surface can work as an environmental shield for protecting products and extending shelf life through noise, vibration, and shock.

2. Improved Shelf Appeal

You can make your product stand out through overmolding because TPE helps create a visually appealing surface. TPE is available in various colors and you can use it for several finishes. It is possible to overmold a clear TPE surface that carries a corporate message, operation instructions, or a logo on customized or patterned substrates.

3. Lower Costs of Production

Overmolding is a rare technique because it offers value in many ways, while also lowering production costs. This technique minimizes steps involved in manufacturing. For instance, overmolding eliminates the requirement for components assembling and injection molding and also secondary finishing tasks (coating, painting, or priming).

Conclusion

Overmolding is suitable for various applications. It offers multiple advantages, including enhanced product performance, better shelf appeal, reduced production costs, and better visual appeal. However, you must weigh several factors before hiring an overmold supplier for your project.

Those factors include product design, material selection, labor costs, and production volume. Injection molding equipment and tooling budgets are other important factors to keep in mind. Before you hire any supplier, you must inquire about their reputation in the marketplace.

If you still have any questions about overmolding, you can feel free to contact us.