Typically insert molding, or overmolding, requires accurately placing part(s) made from metal or other suitable materials (referred to as the insert) into the mold, closing the mold and then injecting the plastic into and/or around the insert(s). A typical application would be electrical connectors that incorporate machined metallic pins or sockets into a molded plastic housing. Most insert moldings utilize metal parts, including handles, threaded inserts or electrical contacts. Taida uses both vertical clamp and shuttle type plastic injection molding presses for insert molding applications.

Mold design is particularly important for this type of molding. All of the toolmakers used by Taida have extensive experience designing tools for insert molding. Whenever possible, we mistake-proof the insert and mold designs to prevent press operators from incorrectly installing parts in the mold. Our mold designers take into account the maximum material conditions of the insert on one hand and still insure a flash-free molding when inserts are received at less than the maximum material condition. Frequently, Taida uses its molding experience and expertise to make recommendations and incorporate them into the product design.

IMF

The process of in-mold decorating a plastic component consists essentially of 4 stages:
Printing, Forming, Cutting and Molding.

Printing: The printing operation is used to create the decorative appearance of the product. While a variety of standard technologies can be used for this stage, silk screen printing is most commonly used.

Forming: The forming process converts the fl at 2D-printed image into a 3D part which is sometimes referred to as a formed appliqué. This process is sometimes referred to as ‘thermo-forming’ which is a catchall term to include vacuum forming,hydro forming and high pressure forming. In all three of these techniques, the fl at printed image is shaped over or into a tool using negative or positive pressure. The tool can be either male or female, and each type has its own advantages and disadvantages.

Cutting/ Trimming: Cutting of the 3D fi lm may be performed before or after the molding operation depending on a number of factors and usually specifi ed by the IMD supplier.

Molding/Injection: The IMD foil(s) is then placed in the cavity of the mold tool and the required resin is injected behind it. The foil can be manually or robotically placed into the tool depending on the volume required and the need for a fast cycle time. The molding process itself will almost certainly have to be optimized to suit the foil. Since all IMD techniques are intended to create cosmetically attractive parts, it will be clear that care in handling of the product is a key issue.

Advantages:

• Suitable for small to medium-sized product.

• Design Flexibility allows customers to express their personalities while the products are easily manufactured.

• Multiple colors, effects and textures with a single operation that are complete when the part comes out of the mold.

• Legend/graphics wear is almost indestructible with second surface printing.

• A cost effective solution over alternative decorating techniques.

• Changing legends / languages / graphics is very easy by simply changing the printing.

•Only pre-processing (vacuum forming) needed, but no post-processing.