Insert molding service

Insert molding is molding plastic around a non-plastic part to create a part. With 22 years of Insert Molding experience, Rapid-MFG has the equipment and knowledge for all custom Insert Molding needs and solutions. Our capabilities perfectly match custom medium/low volume components and equipment in many industries, including medical and industrial.

Rapid-MFG specializes in insert molding services.

The insert molding process reduces assembly and labor costs, increasing design flexibility and part performance.

Our vertical injection molding machine with a turntable lets us overmold and encapsulate inserts for circuitry, fastening, and connections. Common insert molding products include sensors, switches, connectors, and actuators.

Rapid-MFG’s insert molding capabilities include:

Manual and fully automated operations.
Additional secondary molding.
Blanking.
100% pressure resistance and continuity testing.

Engineering, custom injection molding, and contract manufacturing services are available with our comprehensive technology. Our customers bring demanding applications that require insert molding services, preferably by expert engineers.

Benefits of Insert Molding

Stronger Parts

Complex parts are created through a “one-shot” process that produces stronger parts than other molder processes.

Durable and Flexible Solutions

Insert molding eliminates fastener wear and tear to increase the life of the part.

Cost and Production Time Savings

By replacing secondary operations and components with an insert molding process or component.

Affordable Tooling

Molds designed for vertical operation are generally less expensive than horizontal molds. The reduced setup time makes short runs economical.

Rapid-MFG Insert Molding Services

Cable Overmolds (link to Custom Cable Assembly Manufacturing)

By encapsulating wire harnesses in plastic, cables receive additional durability, ingress protection, and cosmetic appeal. Insert molding can also be used to increase cable flex life with an overmolded bend relief.

Soft Touch Overmolds for Grips, Seals, and Aesthetics

Improve aesthetic and ergonomic design of products through custom insert molding. This may include: Grips for ergonomic enhancement Replacing o-rings and gaskets with a soft touch overmolded feature Adding a soft-touch skin to your design for aesthetics and feel

Custom Connectors (link to Custom Connector Manufacturing)

Insert molding can be used to encapsulate electrical contacts in a hard, durable plastic. These custom connectors can be designed to perfectly fit your application.

Fastener Threads and Studs

Use custom insert molding to encapsulate off-the-shelf female threaded inserts or male studs for better product durability.

Design considerations

Rapid-MFG injection molding services enable you to manufacture parts to meet a variety of functional needs. Unlock the potential of your insert molding project with the following injection molding design considerations:

Insert molding general process information

Maximum part size	800 x 800 x 400 mm 31.5 x 31.5 x 15.7 in
Minimum part size	1 x 1 x 1 mm 0.04 x 0.04 x 0.04 in
Tolerance	Best achievable tolerance: ±0.001″ (0.025mm) Standard: ±0.005″ (0.127mm) For larger part tolerances please contact a Fast Radius engineer
Lead time	As low as 2 weeks for T1 samples After T1 sample approval, lead time for < 10,000 parts is as low as 1 week
Tool validation	Standard process is to produce a small set of T1 samples for approval before initiating full production
Maximum press size	1600T
Minimum order size	100 parts and $5000
Set-up fee	$500 per mold per order (applies to sample runs after initial T1 samples or engineering changes)

Insert molding tooling information

Rapid tooling	Molds with steel cavity and core with a shot life of 5,000-10,000 shots Typically machined in 2 weeks
Production tooling	Steel tool with shot life up to 1M shots Ability to integrate side-pulls or cam-actions Typically machined in 3 weeks
Multi-cavity or family molds	Multiple identical cavities or family of parts machined into a single tool Allows for more parts to be produced per shot, minimizing unit costs
Inserts	Inserts are placed into the mold and molding occurs around them to extend tool life for critical features Allows for inserts such as helicoils to be molded in your design

Thermoplastic injection molding materials

Most common materials	Other supported materials	Additives and fiber
Acrylonitrile Butadiene Styrene (ABS)	Nylon (PA 6, PA66, PA12)	UV absorbers
Polyethylene (PE)	Polycarbonate/Acrylonitrile Butadiene Styrene (PC/ABS)	Flame retardants
Polypropylene (PP)	Polyurethane (PU)	Plasticizers
Polycarbonate (PC)	Polymethyl Methacrylate (PMMA/Acrylic)	Colorants
	High Density Polyethylene (HDPE)	Glass fibers
	Low Density Polyethylene (LDPE)
	Polystyrene (PS)
	PEEK
	POM (Acetal/Delrin)
	Polyethylene Terephthalate (PET)
	Thermoplastic Elastomer (TPE)
	Thermoplastic Vulcanizate (TPV)
	Polyetherimide (PEI)
	Polysulfone (PSU)
	Inquire for additional options

Insert materials

Metal	Plastic
Brass	Polypropylene (PP)
Stainless steel	Polyamide (Nylon)
Aluminum 6061	Acrylonitrile Butadiene Styrene (ABS)
Aluminum 7075

Injection molding finishing and post-processing

We can apply a range of injection molding finishing and post-processing options to insert molded parts:

Insert molding colors, finishing, post-processing

Colors	Finishing and post-processing options
Pantone color matching	Standard SPI finishes (A2-D3)
RAL color matching	Mold-tech textures also available
	Pad printing
	Inserts (e.g. heat stake inserts)
	Light assembly
	Protective packaging / film