Insert Moulding Products refers to products that integrate metal, nuts, electrodes or other prefabricated inserts into plastic parts during the injection molding process. It can significantly reduce the subsequent assembly steps, improve structural strength, save labor costs, and reduce the defective rate. It is now widely used in high-standard industries such as medical devices, automotive parts, consumer electronics, and industrial connectors.
Traditional assembly methods not only involve many steps and large errors, but are also prone to unqualified finished products due to looseness or misalignment. Insert Moulding can solve these defects. With many years of experience in precision mold manufacturing and injection molding, Ebardl provides customers with a one-stop Insert Moulding solution from product evaluation, insert pre-installation solutions, mold design and manufacturing to small batch trial production and mass production delivery.
Ebardl's advantages:
Moldflow analysis support: In the early stage of mold design, Moldflow and other software are introduced for simulation analysis to effectively predict problems such as weld lines, shrinkage, and pores, optimize the structural design and flow channel layout in advance, and ensure a high success rate of product molding.
Complex multi-cavity mold manufacturing capabilities: The experienced mold team can handle high-tolerance insert molding, support multi-material co-injection, and metal/plastic multi-point insert integration.
Quality assurance: From incoming materials to shipment, the entire process is controllable, ISO 9001:2015 certified, and the quality system meets international standards, suitable for high-demand industries such as medical, automotive, and electronics.
Strict quality control process: IQC ensures compliance of raw materials, IPQC ensures that each process is not deviated, and FQC/OQC ensures that each batch of goods is delivered with zero defects
Full-size reports, material certifications, surface treatment reports, RoHS environmental protection reports and other complete information can be provided according to customer needs.
The production workshop is equipped with more than ten advanced injection molding machines, with a tonnage range of 200T ~ 1600T
Equipped with precision CNC machining center, slow wire, spark machine and other mold manufacturing equipment
Equipped with mold temperature control system, central feeding system, dehumidification and drying system to ensure the stability of each injection molding
Support 24-hour shift production 7 days a week, and deliver high-quality batch orders on time
Cooperation process:
1. Just provide the following basic information, we will provide an accurate quotation and delivery time assessment within 24 hours: 3D drawings (STEP / IGS / STL and other formats); insert type and quantity (such as nuts, copper pillars, electrodes, etc.); estimated demand and material requirements (plastic types, etc.)
2. Free DFM analysis service after placing an order, providing professional mold flow analysis for your design to help avoid mold and structure problems. After confirming the DFM report, start mold production. Generally, the T1 sample time is 30-45 days (depending on the product structure and size).
3. Once the T1 sample is confirmed, start mass production. 100% quality inspection before shipment (size report can be attached as needed); provide standard export packaging: blister, shockproof foam, anti-static bag, etc.; support global shipment, air/sea/express delivery is flexible.
Application:
In medical equipment, terminal insert molding ensures stable electrical connections and resistance to disinfection, and is suitable for interfaces between diagnostic equipment and wearable devices. In the automotive industry, plastic and metal composite parts such as control module housings and connectors achieve higher strength and vibration resistance through Insert Molding. In consumer electronics, such as headphones, Type-C connectors, heat sink brackets and other parts, this process can be used to integrate metal inserts with plastic shells to improve structural compactness. In scenarios such as industrial control boxes, nut insert molding greatly improves subsequent assembly efficiency and durability. Ebardl can provide customized Insert Molded Parts solutions for different scenarios, helping engineers optimize product design and accelerate mass production.
FAQ:
1. How to ensure that the metal does not shift during the insert injection molding process?
We use precision mold design combined with insert positioning structure (such as limit grooves, covering steps), with special fixtures to ensure that the insert is stable and does not shift under high temperature and high pressure injection molding.
2. How to track the quality and consistency of each batch of products?
Each batch of products is equipped with a complete quality inspection report, which can provide dimensional measurement records, material certification and insert batch number traceability to ensure that the quality of your project is controllable and the responsibility can be traced.
3. Who is responsible for the custody and maintenance of the mold?
The mold belongs to the customer, and we provide free warehousing and regular maintenance services. Before each mass production, the mold will be cleaned, lubricated and tested to ensure long-term stable production.
4. Does it support automation or multi-cavity mold production?
Support. We have injection molding machines with various tonnages from 200T to 1600T. We can design multi-cavity molds according to production and structural requirements, and match them with automatic insert clamping systems to greatly improve efficiency and reduce unit costs.
5. In addition to injection molding, can you also provide assembly or other secondary processing?
Yes. We provide post-processing services such as painting, silk screen printing, laser marking, ultrasonic welding, assembly packaging, etc., support one-stop delivery, and simplify your supply chain management.