Custom Insert Molding Services

Insert molding represents a specialized injection molding technique that combines different materials into a single, integrated component.

At Fecision, we deliver precision insert molding services that help you reduce costs, improve product performance, and streamline your manufacturing process.

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Fecision's Insert Molding Solutions

What is Insert Molding?

Insert molding is an injection molding process where pre-fabricated components (inserts) are placed into the mold cavity before plastic injection. As molten plastic flows around these inserts, it creates a strong bond, resulting in a single integrated part. This technique allows for combining different materials—typically metal and plastic—into one cohesive component.

Unlike conventional injection molding, insert molding creates components with enhanced functionality by incorporating materials with complementary properties. Metal inserts provide structural strength and electrical conductivity, while plastic offers lightweight, corrosion resistance, and design flexibility.

Tooling for Insert Injection Molding

Our insert molding tooling capabilities deliver precision-engineered molds tailored to seamlessly integrate metal inserts with plastic components, meeting the most demanding requirements for your product applications.

Rapid Tooling

Validate your design before full-scale production with our prototype tooling service. We specialize in aluminum molds that balance speed, affordability, and functionality, enabling small-batch production of injection molding prototypes — typically tens to a few thousand parts.

This allows you to quickly test form, fit, function, material performance, and assembly. Aluminum shortens lead times and lowers tooling costs compared to steel, letting you iterate designs faster with reduced risk.

Production Tooling

Our production molds deliver the durability and precision needed for reliable high-volume plastic parts production. We build high-quality steel molds engineered for long service life, tight tolerances, and consistent quality across hundreds of thousands or millions of parts.

You can benefit from our expertise in material selection, cooling optimization, gate design, ejection strategy, and parting-line engineering—tailored to your resin, geometry, cycle time, and volume targets.

Tooling Materials

The mold tooling used in insert molding must withstand high pressures and temperatures while maintaining precise dimensions. Our tooling options include:

Aluminum

Cost-effective option for prototyping and low-volume production

Stainless Steel

Corrosion-resistant for molding aggressive materials.

P20 Tool Steel

Standard production tooling with excellent durability and moderate cost.

H13 Tool Steel

Heat-treated for extended life in high-volume applications.

Beryllium Copper

Superior heat dissipation for thermally sensitive applications

Materials for Insert Molding

We work with a wide range of materials to meet your specific requirements for performance, durability, and cost-effectiveness.
If you have specific material requirements for the project, our team can also work together to explore customized solutions.

Insert Molded Part Materials

We offer a comprehensive selection of engineering thermoplastics for the molded portion of your components.
Below shows several common types:

Part Materials for Insert injection Molding

Material	Properties	Common Applications
ABS	Impact resistant, good surface finish	Consumer electronics, automotive components
Polycarbonate (PC)	Optical clarity, high impact strength	Medical devices, electrical housings
Nylon (PA6, PA66)	High strength, wear resistance	Gears, bearings, structural components
POM (Acetal)	Low friction, dimensional stability	Precision mechanical parts, fasteners
TPE/TPU	Flexibility, soft touch	Overmolded grips, seals, gaskets

Insert Materials

The insert component provides specific properties that complement the plastic material. Common insert materials include:

Brass – Excellent for threaded inserts due to machinability and corrosion resistance
Stainless Steel – Superior strength and corrosion resistance for structural applications
Aluminum – Lightweight option with good thermal conductivity
Copper – Optimal electrical conductivity for electronic applications
Pre-molded Plastic – Used when combining different plastic types with incompatible processing temperatures
Ceramic – Provides electrical insulation and heat resistance

Insert Molding Technologies

Our professional insert molding facility offers comprehensive capabilities to handle projects of varying complexity and scale.
Let's see our technical parameters to help you determine if your project aligns with our manufacturing capabilities.

Parameter	Capability	Notes
Machine Tonnage	25 – 500 tons	Accommodates small precision parts to large components
Shot Size	Up to 1000g	Varies by material and machine selection
Part Dimensions	Up to 500mm x 500mm x 200mm	Larger parts may require special consideration
Insert Placement	Manual and automated	Automated for high-volume production
Tolerances	±0.05mm (material dependent)	Tighter tolerances available for critical features
Insert Types	Threaded, non-threaded, pins, bushings, electronics	Custom insert designs accommodated

Design for Manufacturability in Insert Molding

Optimizing your design for the insert molding process can significantly improve part quality while reducing costs and production time.
Our engineering team provides comprehensive DFM support to ensure your components are designed for successful manufacturing.

Insert Design Recommendations

Incorporate retention features such as knurls, grooves, or holes to mechanically lock the insert in place
Maintain minimum wall thickness of 0.5-1.0mm around inserts to ensure proper flow and structural integrity
Consider thermal expansion differences between insert and plastic materials to prevent stress cracking
Design for proper insert orientation to simplify placement and prevent misalignment

Plastic Component Design Guidelines

Optimize gate locations to ensure complete filling around inserts without displacement
Include appropriate draft angles (typically 1-3°) for easy part ejection
Avoid sharp corners that can create stress concentrations near inserts
Design uniform wall thickness to prevent warping, sink marks, and voids

Common Insert Molding Design Guide

Insert shifting during injection

Improve mold design with better locating features and optimize injection parameters.

Poor bonding between insert and plastic

Enhance insert surface preparation and select compatible materials.

Stress cracking around inserts

Increase wall thickness and modify design to reduce stress concentration.

Incomplete filling around complex inserts

Optimize gate location and adjust process parameters for better flow.

Utilize Inherent Benefits

Advantages of Plastic Insert Molding

Insert molding combines metal inserts with plastic in one efficient step, offering numerous benefits compared to traditional assembly methods.

Reduced Assembly Costs

By integrating multiple components into a single part, insert molding eliminates secondary assembly operations, reducing labor costs and production time, especially compared to traditional assembly methods.

Enhanced Structural Integrity

The molded plastic forms a permanent bond with the insert, creating a stronger connection than mechanical fasteners. This results in improved durability, better load distribution, and enhanced resistance to vibration and impact.

Design Flexibility

Insert molding allows for complex geometries and integration of multiple functions into a single component. This design freedom enables innovative solutions that would be difficult or impossible to achieve with conventional manufacturing methods.

Improved Reliability

With fewer connection points and assembly interfaces, insert-molded parts have fewer potential failure points. This increased reliability is particularly valuable in critical applications where component failure could lead to system downtime or safety concerns.

Size and Weight Reduction

By eliminating fasteners and combining components, insert molding creates more compact and lightweight parts. This weight reduction is especially beneficial in automotive and aerospace applications where every gram matters for fuel efficiency.

Environmental Benefits

The reduction in parts, elimination of assembly steps, and material optimization contribute to a smaller environmental footprint. Insert-molded components often require less energy to produce and can be designed for easier recycling at end-of-life.

Insert Molding Service for Various Industries

Insert Molding Applications

Insert molding technology serves diverse industries with applications ranging from everyday consumer products to critical medical devices.
Our expertise spans multiple sectors, delivering customized insert molding solutions for various applications.

Automotive

Electrical connectors with embedded terminals
Sensor housings with integrated mounting points
Under-hood components requiring thermal stability
Interior trim with threaded fastening points
Gear systems with metal reinforcement

Medical Devices

Surgical instruments with metal working ends
Drug delivery devices with precise components
Diagnostic equipment with embedded electronics
Implantable devices requiring biocompatibility
Medical connectors with reliable contacts

Consumer Electronics

USB and power connectors with metal contacts
Headphone jacks and audio components
Remote controls with integrated circuit boards
Power supply housings with thermal management
Wearable device components with sensors

Industrial Equipment

Control panels with embedded switches
Bearing housings with metal inserts
Pump components
Electrical enclosures with integrated mounting features

Robotics

End-effector housings with embedded threaded inserts
Servo-motor connectors with molded-in terminals
Robot joint covers with integrated metal bushings
Sensor housings with embedded electrical contacts
Control-module enclosures with molded-in mounting hardware

Aerospace

Lightweight structural components
Electrical connectors
Interior components with flame-retardant properties
Control systems with precise tolerances

Insert Molded Parts

Let's Start!

Take the next step towards realizing your high-performance Liquid Silicone Rubber components.

We are committed to providing tailored solutions that meet your specific application needs and project timelines.

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Insert Molding FAQs

What types of inserts can you use in insert molding?

We commonly work with brass terminals, threaded inserts, electrical contacts, metal pins, bushings, shafts, magnets, screws, and custom metal stampings. Virtually any metal insert that can withstand injection pressure can be used.

How do you ensure strong bonding between the insert and plastic?

We use proper insert surface preparation (knurling, texturing, or coating), optimized material selection, precise mold temperature control, controlled injection parameters, and sometimes mechanical features (undercuts or grooves) on the insert.

Can you do overmolding and insert molding in the same project?

Yes. Many projects combine both techniques — for example, insert molding a metal terminal and then overmolding a second material (soft-touch TPE) in a two-shot process.

What is the minimum and typical order quantity for insert molding?

We support prototype and low-volume runs (50–5,000 pcs) using aluminum tooling, and high-volume production (50,000+ pcs) with hardened steel molds. We’re flexible and happy to scale with your project.

How long does it take to get insert molding tooling and first samples?

Prototype tooling (aluminum) usually takes 2–4 weeks; production tooling (steel) takes 4–8 weeks depending on complexity. First samples are delivered shortly after tool completion.

Related Resources

What Is Film Insert Molding? Process, Advantages, and Design Guide

Custom Insert Molding Services

What is Insert Molding?

Tooling for Insert Injection Molding

Rapid Tooling

Production Tooling

Tooling Materials

Aluminum

Stainless Steel

P20 Tool Steel

H13 Tool Steel

Beryllium Copper

Materials for Insert Molding

Insert Molded Part Materials

Insert Materials

Insert Molding Technologies

Design for Manufacturability in Insert Molding

Insert Design Recommendations

Plastic Component Design Guidelines

Common Insert Molding Design Guide

Insert shifting during injection

Poor bonding between insert and plastic

Stress cracking around inserts

Incomplete filling around complex inserts

Advantages of Plastic Insert Molding

Reduced Assembly Costs

Enhanced Structural Integrity

Design Flexibility

Improved Reliability

Size and Weight Reduction

Environmental Benefits

Insert Molding Applications

Automotive

Medical Devices

Consumer Electronics

Industrial Equipment

Robotics

Aerospace

Insert Molded Parts

Let's Start!

Insert Molding FAQs

Related Resources

What Is Film Insert Molding? Process, Advantages, and Design Guide

Overmolding vs Insert Molding: Key Differences, Materials & How to Choose

Medical Insert Molding: Process, Materials & Design Guide