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Insert Molding

What is the Insert Molding Common Materials and Their Properties?

complex insert molding

 

Insert Molding Common Materials and Properties

 

Material Density (g/cm³) Tensile Strength (MPa) Maximum Operating Temperature (°C) Characteristics Common Applications
PPS (Polyphenylene Sulfide) 1.35-1.37 80-100 200-240 Chemical resistance, thermal stability, mechanical strength Automotive, electrical, industrial applications
PPA (Polyphthalamide) 1.20-1.40 100-150 180-200 High-temperature resistance, mechanical properties, chemical resistance Automotive, electrical components
PBT (Polybutylene Terephthalate) 1.31-1.55 50-70 140-170 Toughness, solvent resistance Automotive parts, electronics, household appliances
PEI (Polyetherimide) 1.27 110 170-200 High mechanical strength, thermal stability Medical devices, aerospace, electrical components
PC (Polycarbonate) 1.20-1.22 55-75 120-130 High impact resistance, transparency Eyewear lenses, medical devices, electronic components
POM (Polyoxymethylene) 1.41-1.43 60-70 100-120 High strength, low friction Gears, bearings, fasteners
Nylon PA (Polyamide) 1.14-1.15 60-80 150-180 High mechanical strength, wear resistance Gears, bearings, automotive components
PA6 (Polyamide 6) 1.13-1.15 60-80 180-220 Excellent toughness, fatigue resistance Automotive parts, industrial machinery, consumer goods
PA66 (Polyamide 66) 1.13-1.15 70-85 190-230 High melting point, improved abrasion resistance High-performance automotive parts, industrial components
PA9T (Polyamide 9T) 1.20 95-120 200-250 Heat resistance, chemical resistance Automotive, electrical, industrial applications
LCP (Liquid Crystal Polymer) 1.35-1.50 90-150 220-260 High mechanical strength, chemical resistance Electrical connectors, circuit boards, medical devices
PEEK (Polyether Ether Ketone) 1.30-1.32 90-100 250-300 Excellent mechanical properties, chemical resistance, thermal stability Aerospace, medical devices, industrial applications

Insert molding is a manufacturing process where pre-formed inserts are placed into the mold, and then plastic is injected around these inserts to create a final part. This method is widely used in various industries such as automotive, electronics, and medical devices. The choice of material is crucial for the performance and durability of the insert molded part. Below is an introduction to some commonly used materials in insert molding and their key properties.

Common Materials Used in Insert Molding

  1. PPS (Polyphenylene Sulfide)

    • Description: PPS is a high-performance thermoplastic known for its chemical resistance, thermal stability, and mechanical strength. It is used in automotive, electrical, and industrial applications.
    • Properties:
      • Density: 1.35-1.37 g/cm³
      • Tensile Strength: 80-100 MPa
      • Maximum Operating Temperature: 200-240°C

  2. PPA (Polyphthalamide)

    • Description: PPA is a high-temperature resistant plastic with excellent mechanical properties and chemical resistance. It is commonly used in automotive and electrical components.
    • Properties:
      • Density: 1.20-1.40 g/cm³
      • Tensile Strength: 100-150 MPa
      • Maximum Operating Temperature: 180-200°C

  3. PBT (Polybutylene Terephthalate)

    • Description: PBT is a thermoplastic engineering polymer known for its toughness and resistance to solvents. It is used in automotive parts, electronics, and household appliances.
    • Properties:
      • Density: 1.31-1.55 g/cm³
      • Tensile Strength: 50-70 MPa
      • Maximum Operating Temperature: 140-170°C

  4. PEI (Polyetherimide)

    • Description: PEI is an amorphous thermoplastic with high mechanical strength and thermal stability. It is used in medical devices, aerospace, and electrical components.
    • Properties:
      • Density: 1.27 g/cm³
      • Tensile Strength: 110 MPa
      • Maximum Operating Temperature: 170-200°C

  5. PC (Polycarbonate)

    • Description: PC is a strong, transparent plastic with high impact resistance. It is used in applications such as eyewear lenses, medical devices, and electronic components.
    • Properties:
      • Density: 1.20-1.22 g/cm³
      • Tensile Strength: 55-75 MPa
      • Maximum Operating Temperature: 120-130°C

  6. POM (Polyoxymethylene)

    • Description: POM, also known as acetal, is a high-strength, low-friction engineering plastic. It is used in precision parts such as gears, bearings, and fasteners.
    • Properties:
      • Density: 1.41-1.43 g/cm³
      • Tensile Strength: 60-70 MPa
      • Maximum Operating Temperature: 100-120°C

  7. Nylon PA (Polyamide)

    • Description: Nylon is a strong and flexible plastic known for its high mechanical strength and resistance to wear and abrasion. It is used in gears, bearings, and automotive components.
    • Properties:
      • Density: 1.14-1.15 g/cm³
      • Tensile Strength: 60-80 MPa
      • Maximum Operating Temperature: 150-180°C

  8. PA6 (Polyamide 6)

    • Description: PA6 is a type of nylon with excellent toughness, fatigue resistance, and wear resistance. It is used in automotive parts, industrial machinery, and consumer goods.
    • Properties:
      • Density: 1.13-1.15 g/cm³
      • Tensile Strength: 60-80 MPa
      • Maximum Operating Temperature: 180-220°C

  9. PA66 (Polyamide 66)

    • Description: PA66 is another type of nylon known for its higher melting point and improved abrasion resistance. It is used in high-performance automotive parts and industrial components.
    • Properties:
      • Density: 1.13-1.15 g/cm³
      • Tensile Strength: 70-85 MPa
      • Maximum Operating Temperature: 190-230°C

  10. PA9T (Polyamide 9T)

    • Description: PA9T is a high-performance nylon with excellent heat resistance and chemical resistance. It is used in automotive, electrical, and industrial applications.
    • Properties:
      • Density: 1.20 g/cm³
      • Tensile Strength: 95-120 MPa
      • Maximum Operating Temperature: 200-250°C

  11. LCP (Liquid Crystal Polymer)

    • Description: LCP is a thermoplastic with high mechanical strength and chemical resistance. It is used in electrical connectors, circuit boards, and medical devices.
    • Properties:
      • Density: 1.35-1.50 g/cm³
      • Tensile Strength: 90-150 MPa
      • Maximum Operating Temperature: 220-260°C

  12. PEEK (Polyether Ether Ketone)

    • Description: PEEK is a high-performance engineering plastic with excellent mechanical properties, chemical resistance, and thermal stability. It is used in aerospace, medical devices, and industrial applications.
    • Properties:
      • Density: 1.30-1.32 g/cm³
      • Tensile Strength: 90-100 MPa
      • Maximum Operating Temperature: 250-300°C
 
Reinforced Plastic Additives for Injection Molding
Additive Name Function Common Applications
Glass Fiber Increases tensile strength, stiffness, dimensional stability Automotive components, electrical enclosures, structural parts
Carbon Fiber Provides high strength-to-weight ratio, increased stiffness, electrical conductivity Aerospace parts, sporting goods, high-performance automotive components
Mineral Fillers Improves dimensional stability, heat resistance, reduces cost Construction materials, electronic housings, appliances
Flame Retardants Reduces flammability, slows down combustion Electrical and electronic components, building materials, transportation interiors
Impact Modifiers Enhances toughness, impact resistance Automotive bumpers, housings for power tools, sports equipment
UV Stabilizers Prevents degradation from UV exposure Outdoor furniture, automotive parts, agricultural films
Antistatic Agents Reduces static electricity buildup Electronic components, cleanroom supplies, packaging materials
Conductive Fillers Provides electrical conductivity EMI/RFI shielding, electronic housings, battery components

Introduction to Reinforced Plastic Additives for Injection Molding

Reinforced plastic additives are crucial in enhancing the properties of plastic materials used in injection molding. These additives can significantly improve the strength, durability, and functionality of the final products. Below is an overview of common reinforced plastic additives, their functions, and typical applications.

Common Reinforced Plastic Additives for Injection Molding

Glass Fiber

  • Function: Increases tensile strength, stiffness, and dimensional stability.
  • Applications: Automotive components, electrical enclosures, structural parts.

Carbon Fiber

  • Function: Provides high strength-to-weight ratio, increased stiffness, and electrical conductivity.
  • Applications: Aerospace parts, sporting goods, high-performance automotive components.

Mineral Fillers

  • Function: Improves dimensional stability, heat resistance, and reduces cost.
  • Applications: Construction materials, electronic housings, appliances.

Flame Retardants

  • Function: Reduces flammability and slows down combustion.
  • Applications: Electrical and electronic components, building materials, transportation interiors.

Impact Modifiers

  • Function: Enhances toughness and impact resistance.
  • Applications: Automotive bumpers, housings for power tools, sports equipment.

UV Stabilizers

  • Function: Prevents degradation from ultraviolet light exposure.
  • Applications: Outdoor furniture, automotive parts, agricultural films.

Antistatic Agents

  • Function: Reduces static electricity buildup.
  • Applications: Electronic components, cleanroom supplies, packaging materials.

Conductive Fillers

  • Function: Provides electrical conductivity.
  • Applications: EMI/RFI shielding, electronic housings, battery components.
 
Chemical Additives for Plastic Injection Molding
Additive Name Function Common Applications
Plasticizer Improves plastic flow, reduces brittleness Flexible PVC, rubber products
Filler Reduces cost, improves strength, enhances heat resistance Construction materials, automotive parts
Colorant Adds color for aesthetics or functional purposes Consumer goods, packaging
Lubricant Reduces friction, improves mold release Gears, bearings, fasteners
Curing Agent Promotes hardening by cross-linking polymers Epoxy resins, coatings
Fire Retardant Reduces flammability, slows combustion Building materials, electronics
Blowing Agent Creates foam by generating gas during heating Insulation, packaging materials
Antistatic Agent Prevents static charge buildup Electronics, cleanroom supplies
Degradable Additive Enables plastic to decompose over time Disposable packaging, agricultural films
Heat Stabilizer Prevents degradation from heat PVC products, automotive components
Antioxidant Prevents oxidation from heat, light, radiation Plastic films, food packaging
Antiozonant Prevents degradation from ozone exposure Rubber products, outdoor applications
UV Stabilizer Prevents degradation from UV exposure Outdoor furniture, automotive trim

Chemical additives are essential in the plastic injection molding process to enhance material properties and aid manufacturing. These additives serve various purposes, including improving flow, reducing costs, increasing strength, and preventing degradation. Below is an overview of common chemical additives used in plastic injection molding, their functions, and typical applications.

Common Chemical Additives for Plastic Injection Molding

Plasticizer

  • Function: Improves plastic flow, reduces brittleness.
  • Applications: Flexible PVC, rubber products.

Filler

  • Function: Reduces cost, improves strength, enhances heat resistance.
  • Applications: Construction materials, automotive parts.

Colorant

  • Function: Adds color for aesthetics or functional purposes.
  • Applications: Consumer goods, packaging.

Lubricant

  • Function: Reduces friction, improves mold release.
  • Applications: Gears, bearings, fasteners.

Curing Agent

  • Function: Promotes hardening by cross-linking polymers.
  • Applications: Epoxy resins, coatings.

Fire Retardant

  • Function: Reduces flammability, slows combustion.
  • Applications: Building materials, electronics.

Blowing Agent

  • Function: Creates foam by generating gas during heating.
  • Applications: Insulation, packaging materials.

Antistatic Agent

  • Function: Prevents static charge buildup.
  • Applications: Electronics, cleanroom supplies.

Degradable Additive

  • Function: Enables plastic to decompose over time.
  • Applications: Disposable packaging, agricultural films.

Heat Stabilizer

  • Function: Prevents degradation from heat.
  • Applications: PVC products, automotive components.

Antioxidant

  • Function: Prevents oxidation from heat, light, radiation.
  • Applications: Plastic films, food packaging.

Antiozonant

  • Function: Prevents degradation from ozone exposure.
  • Applications: Rubber products, outdoor applications.

UV Stabilizer

  • Function: Prevents degradation from UV exposure.
  • Applications: Outdoor furniture, automotive trim.
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