Insert injection molding

Insert molding refers to the process of injecting resin into a pre prepared dissimilar material insert into a mold, and then bonding and curing the melted material with the insert to produce an integrated product. Injection molding on the substrate refers to the process of embedding injection molded parts locally on the surface of a metal plate.
The above two forming methods are essentially the same, with the following characteristics.
The combination of resin's formability, flexibility, and metal's rigidity, strength, and heat resistance can be used to make complex and exquisite metal plastic integrated products.
Especially by utilizing the combination of resin insulation and metal conductivity, the molded products can meet the basic functions of electrical products.
3. The pre forming combination of multiple inserts makes the post engineering of product unit combinations more reasonable.
4. Embedded products are not limited to metals, but also include various types such as cloth, paper, wires, plastics, glass, wood, wire coils, electrical parts, etc.
5. For rigid molded products and bending elastic molded products on rubber sealing pads, the integrated product can be made by injection molding on the substrate, which eliminates the complex operation of arranging sealing rings and makes the automation and combination of subsequent processes easier.
6. Due to the fusion of the material and the metal insert, compared to the pressing molding method, the gap between the metal insert can be designed to be narrower, resulting in higher reliability in the molding of composite products..
7. Choose appropriate resin and molding conditions, that is, for products that are prone to deformation and damage (such as glass, coils, electrical parts, etc.), resin can also be used to seal and fix them.
8. Choose an appropriate mold structure, and the embedded parts can also be completely sealed into the resin.
After the embedded parts are formed, they can also be made into products with hollow grooves after core hole removal treatment.
The combination of vertical injection molding machines, robotic arms, and embedded product alignment devices can achieve automated production in most embedded molding projects.
Precautions for the Design and Selection of Automatic Insert Forming System
1. Metal inserts are prone to uneven shrinkage during molding, and limit tests should be conducted on the shape and dimensional accuracy of important parts in advance.
2. During the injection process, metal inserts are prone to deformation and displacement, and full consideration should be given to the design of mold composition and easy maintenance of the shape of the metal insert mold. For products where the shape of the insert cannot be changed, prior testing is essential.
When using conveyors for the arrangement and separation of metal inserts, the contact between metal inserts and between inserts and vibrating balls can cause slight damage to the surface of the inserts, which affects product quality. The allowable quality limit range should be confirmed in advance.
4. The sawtooth shape, warpage, material thickness difference, diameter difference, and thickness difference caused by coating processing of metal inserts should be measured in advance. On this basis, carry out the design of the matching selection of automation devices and the design of mold construction.
5. Predictable factors that restrict mold construction, such as the location of mold gates and molding cycles, should be addressed in advance or corresponding improvement strategies should be implemented as much as possible.
6. It should be confirmed whether the metal insert needs preheating or drying treatment. The purpose is to ensure product quality and molding stability.
7. The various detection devices installed in the mold are used to ensure stable forming action under the influence of environmental conditions such as heat, force, and vibration. It should be confirmed whether to use them.
In order to avoid the accumulation of fine pieces of metal inserts and formed products in the mold cavity, an air blowing device can be assembled if necessary.
Due to the high investment price of system equipment, it is necessary to fully consider whether it can ensure the production volume after equipment operation before adoption. When using specialized machines, it is necessary to ensure that the product can be continuously produced without formal updates for several years.
When using general-purpose machines, it is necessary to confirm how many combinations of multiple varieties and small batches of embedded parts are produced. If the overall production cannot be guaranteed in large quantities, it is difficult to recover the fixed assets of each product. In this situation, it is necessary to replace some devices to adapt to the requirements of variety updates within a certain range.
11. The factors and technical decisions that determine the molding rate, productivity, and molding cost of the insert include the accuracy of the metal insert, the shape of the insert, whether the mold is conducive to the molding of the insert, and the shape of the formed product.
The effective combination of injection machines, molds, and automation devices, as well as how to function in a short period of time, is the key to determining the automatic insert molding system.