1. Presented by: Joshua Bush Michael Goetz Michel McCluskey
Insert Molding
Presented by:
Joshua Bush
Michael Goetz
Michel McCluskey

2. Introduction Inserts Provide: Anchorage / Reinforcement
Bearing Surfaces / Shafts
Internal / External Threaded Sections
Thermal or Electrical Conductivity
Positioning
Nameplates / Lettering
Hinging

3. Background and Theory
An insert is an integral part of a plastic molding consisting of metal or other material which may be molded into position or may be pressed into the part after it is molded

4. Basic Operation Types of Inserts Two general types: Molded-In inserts
Post Molded inserts

5. Basic Operation (cont.)
Molded-In Inserts
Typically for internal threads / studs
Metal Inserts
Usually Undercut or knurled so they stay in the part

6. Basic Operation (cont.)
Post Molded Inserts
Uses Molded-in Hole
Press Fit / Ultrasonically Fit / Self- Tapping
Used for Internal Threads usually

7. Basic Operation (cont.)
Other Types of Inserts
Blind-Hole Inserts
Through-Hole Threaded Inserts
Protruding Thread Inserts
Shoulder-Type Inserts

8. Basic Operation (cont.)
Other Types of Inserts (cont.)
Pressed-in Inserts
Expansion Inserts
Self-Tapping Screws
Flat-type

9. Equipment Injection molding machine
Hand/Pneumatic press (for post molded inserts)
Specialized Molds
Pockets to place the insert
Magnetic Insert Holders
Robots / other mechanical ways of putting inserts into molds.

10. Advantages Provide metal threading in a plastic part
Provide for bearing surfaces
Good for anchoring parts in an assembly
Electrical Contacts in a plastic part

11. Disadvantages Floating Crushing
Flow of Material Into an Open Hole Through The Inserts
Flow of Material Into Blind-hole Inserts
Protruding Inserts

12. Plastic Part Design Standards
Dimensions/Tolerances:
Thread dimensions critical.
Exterior Dimensions/Knurling not as Critical.
Tolerances:
Length +/ in.
Diameters +/ in.
Angular +/- 1 degree max.

13. Minimum Wall Thickness Around Inserts
Dependant Upon
Shrinkage of Plastic
Coefficient of Expansion (plastic and inserts)
Temperature Range of Inserts
Moisture Sensitivity of Plastic Resin
Design of Insert

14. Minimum Wall Thickness Around Inserts (cont.)
Try To Keep Wall Thickness Around Inserts Nominal
Put Inserts in Bosses or Gussets

15. Mold Design Suggestions
Ejectors on the Inserts
Post Inside the Mold to Hold Inserts
Magnetic Insert Holders

16. Selection of Metal For Inserts
Refer to Data Sheets from Material Supplier
Essential Due To Coefficient of Expansion
Must Be The Same

17. Materials Used For Inserts
Aluminum
Brass
Copper
Carbon Steel
Alloy Steel
Stainless Steel
Silver and Other Precious Metals

18. Insert Illustrations

19. Conclusions
Through the use of inserts, a plastic part can be used in applications where once only metal could be used. Good thread, pin, and bushing properties can now be obtained in plastic parts through the use of inserts.

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21. THANK YOU