Insert molding, over molding, double shot molding, and more – these terms are well-known in the realm of plastic production. However, for new buyers seeking custom plastic injection molding services, there may be many questions. Such as what exactly are these production processes? What types of OEM plastic accessories are they suitable for? Do they align with budget requirements?

In today's manufacturing landscape, the demand for plastic accessories continues to grow, and choosing the right injection molding process is crucial for ensuring product quality, cost-effectiveness, and production efficiency. This article will introduce key concepts and features of common injection molding processes, focusing on those frequently used for producing OEM plastic components in small appliances. These processes include:

Insert Molding:

Insert molding involves placing metal or other materials into a mold and injecting plastic around the insert to form the desired shape. For custom small appliance plastic components, insert molding ensures a strong bond between plastic parts and metal inserts, providing strength and functionality. For instance, in OEM HEPA air purifier accessories, metal filters can be inserted into molds, then inject plastic to form the filter in one go. That will make the filter structurally stronger and less susceptible to damage.

Pros: High strength and stability. Saves assembly time and costs. Offers design flexibility.

Cons: Initial costs may be higher. Requires the production of inserts. Just suited for specific designs.

Double Shot Molding:

Double shot molding, also known as multi-shot molding, it is a process that injects different colors or materials during a single injection molding cycle. The process involves injecting the first material to form a base and then molding other materials or multiple materials around the base. After curing and cooling the base, it is transferred to another chamber in the mold for the injection of another material or color. This technique suits products requiring segmentation of different colors or materials, such as decorative parts in OEM appliances or some tool handles that require anti-slip rubber pads, etc.

Pros: Manufactures multicolored or multi-materia products. Reduces assembly steps.

Cons: Requires more complex molds. Higher initial investment. Longer production time, better suited for large-scale production.

Over Molding:

Similar to two-shot injection molding, over molding is a multi-injection molding process. Unlike double shot molding, over molding requires multiple injection cycles to complete the process. In the over molding production process, a base material is first produced using standard injection molding, and after the base material cools and solidifies, it's transferred to a separate over molding mold for over molding. This process adds a material layer to the part, enhancing its appearance, texture, or functionality. For instance, using this process to manufacture the housing of an OEM household humidifier can add a rubberized layer for improved grip and aesthetics.

Pros: Add additional features to products. Enhances appearance and touch.

Cons: Complex manufacturing process, potentially increasing production time and costs. Careful consideration of material selection and adhesion is required.

Gas-Assisted Injection Molding:

Gas-assisted injection molding involves injecting nitrogen or other inert gases during the injection process to create internal cavities within the plastic part. These cavities are then vented once the plastic part cools and solidifies. This method effectively reduces part weight and improves aesthetics. As a result, it's commonly applied to some special appliance parts. It's also used to produce various items, such as chair backs and automotive components.

Pros: Reduces part density, enhances appearance quality, reduces material usage.

Cons: Requires gas injection equipment, higher costs. Careful gas distribution control is necessary to avoid defects.

In-Mold Labeling (IML):

IML (In-Mold Labeling) is an injection molding process of adding patterns and functions to a product's surface during it. It involves sandwiching a film with patterns or functions within a mold and injecting melted material. IML enhances your product's surface with unique characteristics that traditional processes like painting, silk printing, or pad printing cannot achieve. This injection molding process is frequently employed in manufacturing small appliance components and automotive parts.

Pros: Provides durable patterns or labels, elevating product quality.

Cons: Requires specialized equipment and label materials, slightly increasing manufacturing costs.

By familiarizing yourself with these common injection molding processes, you can better select the method ideal for producing your OEM small appliance parts. Whether it's the IML process, insert molding, or double-shot molding, each technique has unique advantages and limitations. Depending on your design requirements, budget, and product performance needs, you can choose the most appropriate injection molding process to achieve high-quality custom plastic components.

ATYOU Health Tech is an experienced small appliances custom production service provider. With our own research and development department, mold factory, injection factory, and assembly factory, we can provide you with professional technical support and production solutions for your custom plastic component injection production needs. Whether OEM plastic component production, customized development of ODM small appliances, or other custom manufacturing needs, we offer tailored production services to meet your requirements and ensure your products meet the expected quality standards. Contact us for more information and to explore the injection molding processes that best suit your product.