Insert Molding Services
Expert Insert Molding Services for High-Quality Parts
Overmolding lets you join two materials into one part, giving it better grip, sealing, or flexibility without extra assembly work.
At Aprios, we take on the daily problems that can come with plastic overmolding. Sometimes that means figuring out how to get more materials to stick together; other times it’s about controlling stress where they meet, or staying in line with regulations for medical or industrial use. Each step is planned so the layers work together instead of pulling apart later. Our engineers have spent years on the floor running injection molding processes and additive manufacturing projects, and that hands-on experience shows in all the custom plastic parts we make.
Custom Insert Molding for Your Product Needs
Each project is built around your product’s exact requirements, and customer collaboration drives every step, defining insert placement, refining geometry, and selecting materials that bond and perform reliably. With deep tooling knowledge and a practical DFM service, teams solve issues early, shorten cycle times, and maintain consistent quality. From prototype to production, the process adapts to your manufacturing goals while protecting precision, repeatability, and long-term performance. Every detail is reviewed, tested, and validated to ensure dependable results.
Our Insert Molding Capabilities
Aprios offers a full range of insert molding capabilities, including multi-cavity tooling and both side-entry and drop-in insert options. Complex geometries and precision fits are handled in-house, supported by dedicated tool maintenance and validation. Our team also manages overmolding and insert molding combinations to create reliable composite assemblies in a single cycle.
Materials for Insert Molding
We work with a broad range of engineering-grade thermoplastics (e.g., PEEK, polycarbonate, ABS, nylon) matched to your performance needs. Resin chemistry is selected to bond securely around metal inserts, handle thermal stress, and maintain dimensional stability once the molten plastic cools. Metal inserts are available in multiple alloys to match thermal expansion rates and support mechanical load requirements.
Why Choose Aprios for Insert Molding?
You gain a partner experienced in overmolding and insert molding, backed by stringent quality systems (ISO 13485 / 9001) and proven production environments. Our vertically integrated tooling, molding, and secondary capabilities cut handoffs and lead time while reducing overall project risk. We bring both engineering rigor and manufacturing craftsmanship to your part.
We're Here to Help You Succeed
From concept to production, we align ourselves with your goals. The project managers at Aprios will act as your advocate, anticipating issues, communicating proactively, and ensuring your insert molded parts meet your budget, schedule, and quality targets. With Aprios, you’re not a number to us; you’re a collaborator in every molding process step.
Insert Molding Process
We begin by placing inserts into the mold cavity, securing them firmly in place. Then molten plastic is injected around or through the inserts under pressure, creating a single, unified part. After cooling and ejection, we inspect for insert positioning, adhesion, and structural integrity. Our process handles tight tolerances and complex geometries reliably.
Frequently Asked Questions
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What is insert injection molding?
Insert injection molding is a process where metal components (inserts) are placed into the mold and molten plastic is injected around or into them, producing a single part with embedded metal features. This method ensures strong adhesion and mechanical integration.
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What are the benefits of using insert molding services?
Insert molding strengthens parts and keeps everything aligned. Metal inserts are built in during molding, so fewer steps are needed later. The result is tighter fits, better seals, and parts that hold up under daily use.
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What industries use plastic insert molding?
Industries such as medical devices, automotive, aerospace, electronics, consumer appliances, and industrial machinery often rely on insert molded parts where plastic and metal must function together in pretty demanding environments.
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What are typical lead times for insert molding services?
Lead times depend on tooling complexity, insert supply, and run size. For simple molds, lead times may range from 4–8 weeks. More complex or multi-cavity tooling can take 8–12+ weeks. Prototyping cycles may be faster.
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What is the difference between insert molding and overmolding?
Insert molding embeds rigid inserts (often metal) into plastic, while overmolding adds a second layer of plastic over an existing part. Both use molten plastic in a molding process but address different design needs.
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Can Aprios assist with design and prototyping?
Aprios supports projects from concept through validation. The team provides DFM service, rapid prototyping, mold trials, and pilot runs to confirm geometry, insert placement, and process settings before moving into full production.
Ready To Get Started?
From design to production, Aprios is ready to support your project. Request a quote today and get started!