Efficient, repeatable molding for durable OEM components with embedded inserts
Hansen Plastics provides custom insert molding services for OEM components that require embedded metal or custom inserts, stronger fastening points, and fewer secondary assembly steps. Our team supports the process from insert and material evaluation through tooling strategy, molding, and inspection to help produce durable, repeatable components for demanding applications.
Insert molding is a manufacturing process that molds plastic directly around a pre-placed insert, such as a metal threaded insert, bushing, pin, or custom component. This approach can reduce assembly steps, strengthen part performance, and create cleaner, more reliable sub-assemblies for demanding applications.
- Reduce assembly time: combine multiple components into one molded part
- Improve durability: stronger retention and more reliable mechanical bonds
- Repeatable results: consistent insert placement and part geometry
- Cleaner assemblies: fewer secondary operations and fastening steps
What is Insert Molding?
Precision Engineering for Complex Applications
Insert molding is a type of injection molding that forms plastic around an insert placed in the mold before injection. Inserts can be metal or other materials and are used to add strength, threaded fastening points, electrical contact surfaces (when applicable), or structural reinforcement. The result is a single, integrated component designed to reduce assembly complexity and improve long-term performance.
Insert Molding Process: How It Works
Step-by-step overview
- Part + insert evaluation to confirm insert type, location, and performance requirements
- Material selection based on mechanical needs, temperature exposure, and environment
- Tooling strategy designed to support stable insert placement and repeatable geometry
- Insert placement (manual or automated depending on the application)
- Injection and molding to form a secure bond around the insert
- Cooling, ejection, and inspection based on required tolerances and quality checks
Insert Molding Applications
Insert molding is commonly used when parts need embedded fastening points, improved strength, or integrated subcomponents. It is especially useful for components that would otherwise require secondary assembly, adhesives, or multiple fastening steps.
Common insert types
- Threaded inserts
- Bushings, pins, and sleeves
- Custom metal components or reinforcement elements
Common part examples
- Housings and enclosures with embedded fastening points
- Brackets and structural supports
- Wear-prone components requiring reinforcement
- Components that benefit from reduced assembly steps
Benefits of Insert Molding
- Fewer manufacturing steps by integrating inserts during molding
- Improved reliability with stronger retention and consistent placement
- Better performance for parts exposed to vibration, stress, or repeated fastening cycles
- Cost efficiency by reducing labor, fasteners, and secondary operations
Insert Molding Capabilities
Hansen Plastics supports insert molding applications that integrate functional or structural components directly into the molded part. Depending on the design and performance requirements, insert molding may incorporate:
- Threaded metal inserts
- Bushings, pins, and sleeves
- Reinforcement components
- Custom metal inserts
- Manual or automated insert placement, depending on the application
- Vertical insert molding for applications that benefit from gravity-assisted insert placement
For parts that specifically require a vertical molding configuration, learn more about our vertical insert molding capabilities.
Ready to Discuss an Insert Molding Project?
Advanced Equipment and Experienced Team
If your component requires embedded inserts, improved retention, or fewer secondary assembly steps, Hansen Plastics can help evaluate the part, materials, tooling strategy, and production approach. Contact our team to discuss your insert molding requirements.
Why Choose Hansen Plastics for Custom Plastic Injection Molding?
Advanced Technology
Utilizing the latest in injection molding equipment and software
Expert Team
Highly skilled engineers and technicians with decades of experience
Quick Turnaround
Efficient processes to meet your deadlines
Exceptional Quality
Rigorous quality control measures ensure consistent, high-quality parts
Testimonials
“My company is in the water delivery business. My role in the company is a Senior Buyer. I have been doing business with HPC for 4 years, however, the company I represent has been doing business with HPC for over 30 years. During that time I have f... Read More
– Scott Olberding, Senior Buyer, Elkay
“My company is in the Automotive tool business. My role in the company is President. I have been doing business with HPC for 12 years. During that time I have found HPC to be Informative… Once expectations are understood, HPC is an excellent comm... Read More
– Eric Leicher, President, Motive Products
“Because of your support, we will be able to provide our guests with a safe place to sleep, food, clothing, coats, shoes, a hot shower, and laundry facilities.”... Read More
– Sarah J. Ponitz, Executive Director, Pads of Elgin
Industries We Serve with Custom Plastic Injection Molding
Appliances
We provide custom plastic injection molding solutions for the appliance industry.
Fluid Movement
Innovative plastic solutions for fluid movement and water treatment industries.
Transportation
Providing high-quality plastic components for the transportation industry.
