Insert Overmolding

Insert Overmolding – Surface Finishing – Polish/Texture

Surface treatment plays a vital role in the manufacturing of plastic products. Ensure that the green surface of Mark 1 in the picture is polished to a B2 rating.

Insert Overmolding – Parting Line Design

The position marked by the red line in the figure below is the parting line design for Insert Overmolding Product.

Insert Overmolding – Draft Angle Analysis

Picture 1: At point 1 these green surfaces are 0 degrees and it is recommended that the material be reduced to mark 2-degree cavity side draft angle. At 2, since the green surfaces are 0 degrees, it is recommended that the material be reduced to mark 1-degree cavity side draft angle to facilitate smooth demolding. By making this adjustment, the demolding of the part can be achieved more efficiently, reducing the wear of the mold on the product, and improving productivity and product quality at the same time.

Picture 1: At point 1 these green surfaces are 0 degrees and it is recommended that the material be reduced to mark 0.5-degree core side draft angle. At 2, since the green surfaces are 0 degrees, it is recommended that the material be reduced to mark 1-degree cavity side draft angle to facilitate smooth demolding. 

Insert Overmolding – Sub-Insert Design

Picture 1:  Point 1 is the core insert pins of insert over-molding products, and point 2 of red lines is the insert pins parting line.

Picture 2:  Point 1 is the cavity insert pins of insert over-molding products.  Point 2 of the red lines is the insert pins parting line. Install these 3 metal inserts onto the three cavity insert pins at location 2. Ensure that each insert is properly aligned and securely fastened to ensure good stability and accuracy of the mold during use.

Insert Overmolding – Ejector Design

In the insert overmolding product mold ejector system, we use the following ejector pin quantities to ensure fast demolding, Ø5/32″ ejector pin*6, Ø3/8″ ejector pin*16, Ø7/32″ * Ø11/32″ ejector sleeve*3, and Ø1/4″ * Ø3/8″ ejector sleeve*3. ” * Ø11/32″ ejector sleeve*3, and Ø1/4 “x Ø3/8” ejector sleeve*3.

Insert Overmolding – Gate Type & Location & Size

The insert overmolding system is equipped with a cold runner with sub gate, gate size is 2×3.5mm This design helps to optimize material flow, ensure uniform mold filling, reduce scrap and increase productivity. The cold runner system effectively controls melt temperature and reduces heat loss, while the sub gate allows for more precise control of plastic inflow, resulting in improved quality and consistency of the finished product.

Mold Problems For Insert Overmolding

Picture 1: It is recommended that material be reduced in the ribs in the red area to change the core side draft angle to 1 degree. This adjustment would need to be made at a total of 24 locations. By changing the side draft angle from the current angle to 1 degree, the demolding can be significantly improved, reducing the amount of material that can accumulate or be difficult to remove from the mold.

Picture 2: It is recommended that the material be reduced in the blue area to adjust the cavity side draft angle to 1 degree. This adjustment will be applied to 3 different positions. By changing the side pullout angle from the current angle to 1 degree, the demolding performance can be effectively improved and potential problems caused by material buildup can be reduced.

Picture 3: It is recommended that the material be reduced in the red area to change the cavity side draft angle to 1 degree. By changing the side pullout angle from the current angle to 1 degree, the demolding performance can be effectively improved and potential problems caused by material buildup can be reduced.

Picture 4: It is recommended that these 3 red holes be treated with material reduction by adjusting the core side draft angle to 0.3 degrees. With this adjustment, the demolding performance can be effectively improved to ensure smoother part removal.

Picture 5: It is recommended that the size of these 3 pointed holes be adjusted from Ф5.5 mm to Ф6.5 mm so that the screw inserts can kiss of with the insert pins and thus effectively seal the plastic. This adjustment ensures a perfect fit between the screw inserts and the mold, avoiding plastic leakage or uneven flow and further improving the sealing and molding quality of the mold.

Picture 6: It is recommended that a 0.2×2.5mm undercut (red surface show) be added to the inside of the part to prevent the part from sticking to the cavity side during the demolding process. This undercut design is effective in reducing plastic adhesion inside the mold and ensures that the part will demolding smoothly from the mold, thus increasing productivity and reducing potential demolding problems.

Mold Layout For Insert Overmolding

Reasonable mold layout design needs to take into account factors such as the injection molding machine, mold, cooling system, operating space and molded product removal to ensure the efficient operation of the production process and the quality of the final product.

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