Micro Insert and Over Molding

Insert micro molding can provide an excellent alternative for the manufacturing of micro devices. Our plastic injection molding equipment is specifically engineered for insert micro molding and has twice the precision and repeatability as conventional molding equipment. This enables us to achieve tolerance targets on complex components that conventional molders cannot maintain; and streamlines the manufacturing process to create a more robust and reliable design for manufacturing.

A pair of paper clips and a tooth pick on top of a table.

Insert Micromolding Tip 2
Micro Insert & Over Molding

A tiny piece of plastic is sitting next to a penny.

Over Micromolding Gear
Micro Insert & Over Molding

A close up of a metal object on top of a table.

Insert Micromolding Tip 1
Micro Insert & Over Molding

A blue cable is laying on the floor

Insert Micromolding Stylet
Micro Insert & Over Molding

A penny with a blue piece of plastic on it.

Insert Micromolding Part 1
Micro Insert & Over Molding

A tiny needle sitting on top of a coin.

Insert Micromolding Needle
Micro Insert & Over Molding

There are numerous benefits to employing insert micro molding technology in the manufacturing of new and existing work devices. These include:

  • Minimal or zero dependency on microscope to assemble
  • Elimination of expensive machined components
  • Reduction or elimination of secondary operations
  • Increased production yields
  • Decreased manufacturing cycle time
Some of the most common micro molding materials we work with include (but are not limited to):ABS: Acrylonitrile Butadiene Styrene PEEK: Polyether Ether Ketone PP: Polypropylene LCP: Liquid Crystal Polymer PEI: Polyetherimide TPU: Thermoplastic Polyurethane PPS: Polyphenylene Sulfide PA: Polyamide PET: Polyethylene Terephthalate PPS: Polyphenylene Sulfide PBT: Polybutylene Terephthalate POM: Polyoxymethylene PSU: Polysulfone PC: Polycarbonate PMP: Polymethylpentene

Micro Insert and Over Molding FAQs

Micro insert and over molding are similar but distinct processes. Micro inserting is a process which molds a separate part, often of another type of material, over an existing part, such as a wire. Over molding entails molding one part and then molding a second part over it.

Our plastic injection molding equipment is specifically engineered for insert micro molding and has twice the precision and repeatability as conventional molding equipment. This enables us to achieve tolerance targets on complex components that conventional molders cannot maintain; and streamlines the manufacturing process to create a more robust and reliable design for manufacturing.

We employ both manual and automated insert molding, and typically work with lumens, wires, marker bands, and needles. To mold over an object such as a needle, for instance, our operator will load the object into a mold tool by hand. In our automated process, we use end-of-arm tooling designed for the object to load into the mold.

We provide full-service over molding. The process entails our molding the first part and then molding a second part, often of a different material than the first, either manually or with a robotic arm to perform the insertion. For instance, in over molding a micro gear, we will mold the magnetic part first, then insert a tiny bushing into the mold tool that we mold the second part over. With a 0.1 in-diameter bushing, there is literally no clearance and no room for error!