Insert Molding Services

Providing custom insert molding services, assisting with design optimization, material selection, and complex geometry tooling to meet your unique project requirements from concept to production.

ISO certified

No minimums

A wide range of material and finishing options

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What is Insert Molding?

Insert molding is a specialized injection molding process in which a pre-formed component—typically metal, but also plastic or other materials—is placed into a mold before molten material is injected around it. As the material cools and solidifies, it forms a strong, integrated bond between the insert and the surrounding plastic, creating a single, durable component. This process is commonly used to enhance part performance by combining the strength, conductivity, or functionality of inserts (such as threaded metal components) with the versatility of molded plastics.

At GSG-Tech, insert molding supports a wide range of thermoplastics and silicone materials, enabling the production of high-quality prototypes and on-demand parts for applications such as functional testing, low-volume production, and bridge manufacturing.

Insert molding is frequently used for:

low-volume production parts
bridge tooling

Materials for Insert Molding

We offer a broad range of thermoplastic and thermoset materials, each selected for its performance characteristics and suitability for different applications.

Metals

Aluminum

Lightweight, corrosion-resistant, and featuring a high strength-to-weight ratio, aluminum is ideal for aerospace, automotive, and construction industries. It is also highly machinable.

Color:

Silver

Grades:Aluminum 5052, 5083, 6061

Lead Time:Approx. 5 business days

Insert Molding Tooling Solutions

Prototype

Rapid Tooling

Get design feedback and validation easily through high-quality prototype tooling. Create low-volume plastic molded parts with excellent injection molding prototypes. We excel at manufacturing prototype molds within days to ensure you can perform functional testing and validate market interest.

Production

Production Tooling

We manufacture high-quality production molds for high-volume plastic part production. Our production tooling uses high-strength, durable tool steel materials suitable for producing hundreds of thousands of parts. We can vary materials and construction methods according to your unique requirements.

Insert Molding Capabilities

GSG-Tech's insert molding solutions can manufacture parts with diverse functional and aesthetic needs. These guidelines will help improve part manufacturability, shorten lead times, and enhance part aesthetics.

Feature

Description

Max Part Size

800×1000×400 mm 31.50×39.37×15.75 inches

Min Part Size

2×2×2 mm 0.08×0.08×0.08 inches

Substrate Wall Thickness

From 0.5 to 3 mm From 0.02 to 0.12 inches

Tolerance

+/- 0.025 mm +/- 0.00098 inches

Insert Materials

Inserts can be male or female; both can significantly improve product aesthetics and functionality.

Tooling Validation

T0, T1, T2 samples provided before mass production

Inspection & Certification Options

FAI (First Article Inspection), ISO 9001, ISO 13485 Certification

Lead Time

From tooling fabrication to sample delivery: 15-45 business days

Benefits of Insert Molding

Insert molding reduces assembly and labor costs, enhances part strength and reliability, and allows for the integration of many materials and complex components.

Eliminate Assembly:Insert molded parts do not require assembly because there is only one manufacturing process.

Reduce Costs:Eliminating the assembly process reduces the cost of the insert molding process compared to standard injection molding.

Reduce Part Size and Weight:Molded parts with inserts weigh less than all-metal parts.

Improve Part Strength:Plastic insert molding securely integrates metal inserts, improving wear resistance and structural integrity compared to traditional assembly methods.

Applications of Insert Molding

Plastic insert molding is suitable for manufacturing prototypes and full products for multiple industries. Main industrial applications include:

Consumer Goods:Custom plastic insert molding is suitable for manufacturing consumer products due to its functional and aesthetic advantages.

Medical Devices:Before choosing insert molding for manufacturing devices like medical implants, ensure the plastic is biocompatible.

Aerospace and Automotive:Applied in aerospace and automotive industries due to the strength and durability of the molded components.

Communication Equipment:Suitable for manufacturing handheld devices such as screwdrivers, scissors, dials, and knobs.

Insert Molding vs. Overmolding

Insert Molding: Integrates pre-formed inserts (mostly metal) into a single molding process to directly form an integrated part. The advantage lies in high single-shot efficiency, enhanced product strength, and reduced post-assembly processes.

Overmolding: A multi-step process that molds one material (usually TPE) onto a rigid substrate. The core advantage is creating parts with different textures and functions (e.g., a toothbrush with a 'rigid core + soft grip').

Both processes have their own focus. Click the video to learn the key differences between them.

Why Choose GSG-Tech

ISO-Certified

Our ISO 9001 and ISO 13485:2016-certified CNC machining process ensures dimensional accuracy, surface integrity, and consistent performance across prototypes and production runs.

98% On Time Delivery

With advanced CNC equipment, optimized scheduling, and an integrated manufacturing network, we deliver parts with industry-leading speed.

15+ Year Experience

Our experience enables us to anticipate challenges early, optimize production processes, and consistently deliver reliable, high-precision parts.

Engineering Support

Our experienced engineering team works closely with you from design to delivery.

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