All About Insert Molding Micro Molding Process

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All About Insert Molding Micro Molding Process

Insert molding micro molding is a method where an already existing manufactured component is
molded from a variety of materials like glass and metals into different types of plastics. This
process of combined micro-molding is either performed by 2-shot molding process or insert
molding process.
Industrial demand for miniaturization in manufacturing parts has encouraged several companies
to produce injection moldings equivalent to the size of 250 microns in diameter and less than
0.10 grams in part weights. This phenomenon has increased the interest of several manufacturers
and designers in micro-featured plastic parts industry, as well as the producing and procuring
high precision sector.
What is Insert Molding?
Insert molding micro molding is a process of combining several parts into one single component
by injecting the thermoplastic around the placed inserts. There are mainly two kinds of plastics,
one is known as the thermosets and thermoplastics. Custom plastic injection molding is the most
common method of manufacturing parts which are made of plastic. However, various parts like
metal stampings, filtration materials, bushings, electromechanical parts and other discrete parts
are involved in this highly efficient process too. This process is further divided into a couple of
classes, all of which possess their own challenges and specific parameters for efficient
production.
There are four major factors that influence this particular process. They are as follows:
The material
The molder
The injection machine
The mold
Of these four elements, the mold and injection machine are the most distinguished and
mechanically diverse elements of this system. Insert molding micro molding can be used
economically to form definite parts in bulk quantities. Parts like these can be found in the
smallest sizes, perhaps, as small as a few tenths of a gram to as big as a long kilometer range.
With insert molding, components or parts can be produced with optimum accuracy. These
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precision driven instruments are mainly used for mass-production or in precision engineering.
Also, a surface of the component can be matched with a given particular requirement.

Different Steps involved in this Process
A custom plastic injection molding is loaded with various inserts.
The inserts can be loaded manually or robotically.
Molten plastic is carefully injected into the mold.
All the components present in the machine are separated from the inspected and spruce.
Cooling of the system enhances the opening of the mold. Furthermore, the components
are removed after the opening.
Post-molding assembly takes place. This process includes a variety of secondary
operations like, bonding, circuit testing, micro-soldering and cutting of stampings into
discrete circuits.
The insert molding micro molding process is quite exclusive and highly economic in business
models. It is mainly used in the field of engineering large quantity productions. Nonetheless,
even for relative conventional tools, the cost of this tool is significantly high. Therefore it is
advised to protect the tooling booth during the shipment and storage periods, as well as during
the processing of the parts.

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