Insert Molding with a Vertical Molding Machine: Process & Advantages

Manufacturing Methods for Tight Tolerance and High Performance

Plastics are the most common materials used in the end-to-end manufacture of everything from consumer goods to medical devices. But the plastics manufacturing process is not a one size fits all situation. Varying types of thermoplastics, specialized injection molding processes, and specifically designed machinery are required to properly manufacture plastic components that meet rigorous specifications — and not all thermoplastics are compatible with all processes or equipment, so customization is key.

One of the processes we specialize in at HPP is insert molding using a vertical molding machine. Insert molding is one of the most cost-effective ways to ensure a component can withstand strong forces, and the vertical molding machine can help increase your cost savings. Let's take a closer look at what insert molding entails, the benefits of using this process, and the advantages of using a vertical molding machine.

What is Insert Molding?

Insert molding is a specialized form of injection molding that involves forming plastic parts around other non-plastic parts called inserts. The final result is a finished plastic product with an embedded or encapsulated wood or metal insert. The insert itself may be functional (such as a metal screwdriver with a molded plastic handle) or included solely for structural support. When it’s done properly, insert molding can result in a stronger, longer-lasting part than standard injection molding. 

Benefits of Insert Molding

One of the greatest benefits of insert molding is its cost-effectiveness. It's a relatively inexpensive way to ensure that your finished component will be stronger and more durable. Additionally, insert molding means fewer assembly steps and lower labor costs without sacrificing speed and precision. It offers design flexibility, increases component reliability, and reduces the size and weight of each part. Products created with insert molding can be used across various industries, including medical, aerospace, energy, industrial, electronics, and the consumer market.

Advantages of Using a Vertical Molding Machine 

Horizontal molding machines were the industry gold standard for years. But today's vertical molding machines are proving to be more sustainable, flexible, efficient, reliable, and able to produce larger parts than their horizontal counterparts. Vertical molding machines help cut costs, reduce waste, and take up less space than traditional machines. 

With a horizontal machine, the molten plastic often travels a longer distance to the mold. That gives the resin time to cool before it's molded, which can result in imperfections and inconsistencies. The vertical molding machine requires a shorter runner since the plastic comes from the top, so the resin has less time to cool. The efficiency of the production cycle means less plastic waste, cost savings, and maximum versatility.