Insert moulding

Glossy polymers can be obtained by polishing, post-moulding into perfectly polished moulds, lay out of films, IMD, FIM (film insert moulding), IMC (in mould coating), painting... 

Processing of LFRT or LFT - long fibre (reinforced) thermoplastics injection, composite insert moulding, compression moulding, extrusion-compression. 

Concurrently, the wear on machinery and mould is higher than for unfilled polymers. The material compositions used so far are unahle to fulfil the demands of upcoming component functionality, particularly for thin-walled and miniaturised elements. Hence, functional components that require high electrical conductivity, are still typically produced in cost-intensive processing and assembly steps (e.g., insert moulding, hot stamping or metallising) [2,4-7]. 

Inclusion of inserts. Best of both worlds solutions are possible by insert moulding of, e.g., brass screw threads, stainless steel bearings, steel cores for close-tolerance gears, etc. With robots the insertion can be very rapid in blow moulding, SMC and GMT processing etc., as well as in injection moulding. 

Another technology available to the component designer is film insert moulding (FIM). This enables complex moulded parts to be created in an efficient and economic manner as, for example, when... 

PPS is an ideal choice for automotive parts exposed to high temperatures, automotive fluids, or mechanical stress. PPS is a lighter weight alternative to metals that is resistant to corrosion by salts and all automotive fluids. The ability to mould complex parts to tight tolerances and insert moulding capability accommodate multiple component integration. 

This technique is where components are placed in an injection mould and are then moulded over with another material. The term over-moulding covers both insert moulding and lost core moulding. This technique is not confined to plastics and over-moulding of metal inserts, such as to produce scissor handles and plastics on ceramics is commonplace. 

In this process, a component termed a preform is placed into the tool of an injection moulding machine. A second material is then moulded onto or around the preform. Two methods fall imder this category insert moulding and lost core moulding. 

Insert moulding with plastics is a two-step process whereby a first preform component is placed into the open mould cavity. Injection then proceeds as with traditional moulding methods with injection of a molten plastic onto the preform. This process is not limited to two material components and the resultant mouldings can be transferred in this way until the required number of layers is achieved. Inserts can be loaded by hand or by the use of robots. Inserts must be accurate in both their dimension and their placement into the over-moulding tool to prevent tool damage and provide accurate registration of one material on another. A means must also exist to hold them in place within the tool. In this way it has similar requirements to that of in mould lamination techniques commonly used to decorate plastics with films or foils, details of which can be found in a specialist Rapra Review Report [4] and will not be covered further here. 

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