Insert moulding is a special injection moulding process in which we mould a thermoplastic around a prefabricated insert, usually made of metal, ceramic or another material. This technique enables the seamless integration of components, eliminating the need for assembly after moulding.
Unlike overmoulding, where a secondary layer is applied to an existing plastic part, insert moulding integrates a specific insert – such as a fastener, sensor or electronic component – directly into the moulded part. For applications that involve metal insert injection moulding or metal insert moulding, the result is a strong bond between materials with excellent performance.
We start the process by placing the insert into the mould cavity, which can be done manually or automatically using robot technology. Once positioned, the mould is closed and molten plastic is injected into the cavity, encapsulating the insert and forming a single, connected component. This ensures precise alignment of the insert while preventing displacement during moulding. The design of the mould cavity is crucial, as it must take into account the positioning of the insert and ensure a consistent flow of plastic around it.
As we at Ensinger provide support from the initial idea, through design and component construction, to prototype production and subsequent series production, we always know where to start in order to guarantee the highest quality standards.
This process is frequently used in sectors such as the automotive, healthcare and electronics industries, where durable, lightweight and high-performance parts are required. Applications include insert moulded parts such as housings for medical devices and gearboxes for motor vehicles.
Insert moulding is typically used for bearing applications. Strict tolerances could not be met if moulded solely in plastic, but the combination of metal and plastic can, making the application lighter and more cost-effective to manufacture.
As an experienced insert moulding partner, Ensinger offers high-precision solutions for a wide range of applications. Our plastic insert moulding parts impress with their precise processing, durable material combinations and top quality. Whether it's heavy-duty hybrid components, metal overmoulding, or specialised industrial parts — with Ensinger, you can rely on durable, innovative solutions.
