An Introduction to Insert Moulding: Creating Stronger, Smarter Components

The pressure is always on to create parts that are stronger, lighter and more cost-effective.

Insert moulding at BEC typically combines metal and plastic in a single manufacturing process, producing components that are quite literally stronger than the sum of their parts.

From medical tools to car parts, this method creates robust products while cutting production time and costs.

Understanding how this process works – and why it matters – helps explain why more manufacturers choose it for complex components.

Here, we’ll explain insert moulding, how it works, and the advantages it can lend to your project.

Understanding the Insert Moulding Process

Metal and plastic each offer distinct benefits in manufacturing but joining them usually requires complex assembly.

Insert moulding takes a different path. Metal parts – such as threads or electronic components – are placed inside a mould tool before the plastic flows in, and around the component.

Once cooled, the single finished part emerges ready to use – no extra assembly needed.

Insert Moulding’s Applications Across Industries

Insert moulding serves critical functions across many sectors, delivering the perfect blend of strength and usability in:

Medical Devices: Surgical instruments combining metal precision with ergonomic plastic grips, dental tools, and diagnostic equipment

Automotive Components: Dashboard controls, engine parts, gear systems, and electrical connectors

Consumer Electronics: Phone casings with embedded metal components, computer parts, and device housings requiring structural integrity

Home Appliances: Kitchen equipment, white goods components, and bathroom fixtures that need water-tight seals

Aerospace: Lightweight yet strong components for interior fittings and control systems

Key Benefits of Insert Moulding

Insert moulding is an established manufacturing technique, but why? Because of several distinct advantages over other manufacturing methods:

Strength: Plastic encapsulates a metal insert, creating exceptionally durable parts

Efficiency: One process replaces multiple assembly steps, reducing production time and cost

Design Freedom: Complex shapes become possible while maintaining structural integrity

Cost: Reducing the amount of metal required, and assembly time can in turn lower costs for production

Weight Reduction: Strategic use of plastic cuts overall weight without compromising durability

Combined, these benefits make insert moulding especially valuable in industries where every gram matters, from aerospace components to portable electronics.

Material Considerations

Creating outstanding insert moulded parts means making smart material choices. Whether plastic or metal, each material plays a vital role in the finished product’s success.

Different plastics serve different needs:

Nylon for raw strength and durability

ABS when you need impact resistance

Polycarbonate for clear, tough components

Metal selection is just as vital:

Brass for threaded inserts – corrosion resistance and lower cost than stainless steel

Stainless steel for medical equipment – meets hygiene standards

Aluminum when weight matters, but strength can’t be compromised

Matching these materials correctly ensures your parts will perform exactly as needed, both during production and throughout their working life.

Ready to Explore Insert Moulding?

Insert moulding demands precision at every stage – from controlling temperatures of both plastic and metal, to perfect insert placement and carefully managed cooling.

Get it right, and you’ll obtain durable, high-quality parts. Get it wrong, and you risk warped components or weakness between the metal and plastic.

At BEC Group, we’ve spent decades mastering these details. Our team will guide you through every step, from choosing materials to optimising your design for production. We make sure your components come out exactly as you need them.

Get in touch to discuss your project – we’ll help you determine if insert moulding could enhance your manufacturing process.

For more information on An Introduction to Insert Moulding: Creating Stronger, Smarter Components talk to BEC Group