Compare The Insert Molding And Over Molding Processes
Insert molding and over molding are injection molding methods used in creating industrial and commercial items. The two use the same idea of molding a plastic part over the other. Though their concepts are similar, their function and properties differ significantly. The variations generally lead to different applications depending on the expected outcome. However, using the two techniques without an in-depth understanding causes adverse effects. Some include wastage of time and materials, product failure, and high production costs. At Creatingway, we offer a guide that helps compare over-molding and insert molding. Here is detailed information to help you choose the correct method for your project.
How to Define and Understand The Over Molding Process?
The over molding uses a molded plastic molding onto another. Such a procedure is also known as a two-shot molding process. First, you inject plastic into the mold, forming a substrate. Upon solidification, place the substrate onto another mold as you inject the second-over mold. Later, after the substrate encapsulates the over mold, ejection occurs.
Uses of Over Molding
Here are ways of using over-molded parts in the commercial and industries;
- Most over-molded parts are compatible with heat, electric shock, and vibrations. Therefore, their use offers greater chances of durability.
- The majority offers a comfortable grip, especially with plastic handles.
- Items with debossed or embossed parts featuring a business logo or name.
- They also offer better aesthetics since molding provides various contrasting colors.
Merits of Over Molding
- The flexibility of a material increases with the use of different plastic parts.
- The connection grip between two plastic materials enhances greatly.
- There isn’t any necessary use of other joining mechanisms like adhesives or plastic welding.
- A product’s performance improves gradually as well as durability.
Demerits of Over Molding
- Several injection molding methods increase the cycling period incurring production costs.
- Some plastic types aren’t compatible with others. Such attributes lead to opting to choose the best material that is costly.
- Optimal temperature ranges cause fluctuations leading to delamination
- Over molding uses more tools than single injection molding due to the involvement of the two-step process.
- In some cases, special tools are essential, which increases developmental costs.
How to Define and Understand The Insert Molding Process?
What Are The Insert Molding Processes?
Insert molding is a process that molds plastic over metals called inserts. The method involves placing an insert in a mold and injecting molten plastic. As cooling occurs, the molten plastic becomes encapsulated in the plastic material. This method occurs in two ways, automated and manual. The manual method is much cheaper and easier to control than the automated one.
Uses of Insert Molding
Insert molding is primarily applied in the medical, aerospace, electronics, and defense industries. Examples of such moldings include; clips, spring contacts, screwdrivers, and pins.
Merits of Insert Molding
- The process reduces the need for part assembly.
- Insert molding creates reusable and robust connections.
- We are to improve the combination of metal and plastic pieces improving part performance.
- Best suited in creating thin-walled cases which are untappable.
- Highly considered for creating items resistant to vibration, dust, moisture, and pull-out.
- The method is affordable as it is cost-effective.
Demerits of Insert Molding
- by using the method, there is an increased likelihood of the resin shrinking and entering the insert, causing problems.
- There are several manufacturing parts in use, such as plastic and metal.
- The parts being complex, there is a need for highly skilled staff to operate the machines.
What Are The Differentiate Between Over Molding and Insert Molding?
Material Selection
Over-molded parts originate from plastic parts that form chemical bonds with each other. Although, not all parts are compatible with each other. Some examples include ABS is compatible with polyethylene, Polycarbonate, and ABS but not POM. However, with insert mold parts, most materials are compatible. Such traits make the method widely selected for its broader material compatibility.
Technique
One of the major differentiating factors between over and insert molding is the process. Whereby molding consists of the two-step manufacturing method of placing an over mold onto a substrate. Alternatively, insert molding places molded plastic on a non-plastic material. Such a process makes insert molding a one-step manufacturing process.
Cost
The two-injection method in over molding makes it more expensive than insert molding. With insert molding, we can reduce assembly costs and improve item productivity. Such reductions make customers opt for the method, as quality is guaranteed.
Production Speed
The two techniques both take time to process. However, over-molding takes lesser time than insert molding. The insert method requires molding a layer onto a product which the total product encapsulates the insert.
Conclusion
Insert molding and over-molding are injection methods that use the same production basis. The concept involves molding a plastic part over another. However, speed, cost, processes, and material selection differ. One must have a broader knowledge of the two before choosing either. That’s why at Creatingway, our team offers the best advice regarding various ways of achieving high-quality over molded or insert molded parts. Contact us when dealing with products requiring either of the two processes to achieve desirable results.
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