SUDACNC delivers professional single-shot insert molding service to encapsulate pre-fabricated metal, conductive terminal or electronic components fully inside molten engineering plastic in one molding cycle. Custom locating mold fixtures, knurl anti-rotation & pull-out interlock design, semi-auto robotic insert feeding, strict positional tolerance control and torque pull-out validation eliminate manual assembly, improve structural rigidity and conductive stability for automotive, medical, electronics and power tool mass production.
ISO 9001, IATF16949, ISO 13485 certified molding workshop
What Is Insert Molding?
Insert molding is a single-shot injection molding process: pre-manufactured rigid inserts (metal fasteners, conductive terminals, shafts, circuit assemblies) are precisely locked into dedicated mold locating cavities first, then molten thermoplastic is injected to fully wrap and encapsulate the inserts, forming a single unified composite part with permanent mechanical interlock bonding.
Different from overmolding (soft TPE coated on finished plastic substrate), insert molding embeds hard functional metal/electronic components deep inside plastic matrix for structural reinforcement, electrical conduction and threaded connection needs. It cuts multiple assembly steps, avoids loose fastener risks and stabilizes dimensional consistency for long-cycle mass manufacturing.
Insert Molding Basics & Standard Production Process
Insert molding encapsulates pre-processed metal, conductive terminal or electronic inserts inside engineering plastic via single-shot injection molding. The full workflow includes insert cleaning/preheating, precision fixture loading (manual low-volume / robotic high-volume), mold clamping, molten plastic full encapsulation injection, cooling ejection and pull-out/torque quality testing. All inserts are locked by mold spring pins or magnetic seats to eliminate floating shift during high-pressure melt injection, forming permanent mechanical interlock composite parts without secondary assembly operations.
Core Advantages of Our Insert Molding Service
Assembly Consolidation: Integrate multiple discrete metal/plastic/electronic parts into one finished component, reduce BOM and assembly labor cost
Permanent Anti-Rotation & Anti-Pullout: Knurl, flange, through-hole interlock design resists torque and axial pulling force for threaded connector applications
Stable Insert Positional Precision: Dedicated mold locating fixture restricts insert offset within ±0.1mm critical datum tolerance
Dual Loading Modes Available: Manual loading for prototype small batches; robotic pick-and-place for high-volume automated mass production
Complete Performance Validation: Pull-out force test, rotation torque test, thermal cycle aging test for automotive & medical compliance certification
Three Main Insert Molding Production Types
Single Metal Insert Molding
Single brass threaded insert, aluminum shaft or stainless pin encapsulated in plastic housing
Full Compatible Insert Materials & Encapsulation Thermoplastic Resins
Material matching must consider thermal expansion coefficient (CTE) difference between metal insert and plastic to reduce interface internal stress and cracking risk.
Brass C36000/C37700: Most popular threaded insert material, balanced machinability & CTE matching with PA/ABS plastics, anti-rust for consumer & automotive assembly
Stainless Steel 304/316: High tensile strength, corrosion resistant for medical and outdoor industrial structural pins/shafts
Aluminum 6061/7075: Lightweight conductive shaft inserts, low cost for power tool rotating core components
Copper / Nickel-Plated Copper: Excellent electrical conductivity for wiring terminal and charging connector encapsulation
1. Spring-Loaded Pin Locating: Standard for small cylindrical brass inserts, elastic pin locks insert without surface scratch, low mold cost for small batch prototype.
2. Magnetic Mold Seat: Permanent magnet embedded in mold cavity base, stable holding force for flat copper terminals, compatible with robotic automated loading high-volume production.
3. Full Contour Stop Seat: Complete insert outer profile matching mold cavity, highest positional precision for critical automotive electrical connectors with tight datum tolerance.
NAK80 Pre-Hardened Steel: Medium volume 300k shots, easy polishing for cosmetic consumer plastic parts with brass inserts.
S136 / STAVAX Stainless Steel: Corrosion resistant for medical transparent resin molding, anti-rust when encapsulating copper conductive terminals, up to 5 million production cycles.
H13 Hot Work Steel: High impact toughness, anti-abrasion for molding glass-filled PA around hard stainless steel inserts to reduce cavity wear.
Set thin 0.015–0.02mm vent channels at plastic-insert bonding interface to exhaust trapped air and eliminate burn marks at composite boundary.
Design side gate rather than direct center gate to avoid unbalanced melt flow pushing inserts offset during high-pressure injection.
Add independent cooling channels around insert locating seats to balance cooling speed between metal insert and plastic matrix, minimize shrinkage stress cracking risk.
Custom Insert Locating Injection Mold Tooling Quotation Service
2. Plastic Cracking Around Metal Insert: Insufficient wrap wall thickness or large CTE difference between metal & plastic; increase plastic thickness or switch lower expansion matching resin.
3. Insert Pull-Out Under Torque: No knurl/flange mechanical interlock; add circumferential knurl retention feature on insert outer surface.
4. Air Burn Mark At Insert Boundary: Insufficient vent channels at bonding interface; add thin vent slots along insert contour edge on mold cavity.
Insert Molding: Pre-made metal/electronic inserts are locked inside mold first, plastic injects to fully encapsulate inserts, bonding relies on mechanical interlock, target for structural reinforcement & electrical conduction parts.
Overmolding: First shoot rigid plastic substrate, then inject soft TPE/TPU thin layer on substrate surface, bonding relies on material chemical compatibility, target for anti-slip grip, waterproof sealing and soft touch ergonomic surface.
Yes, we design custom soft protective mold inserts to shield sensitive PCB chips during mold clamping and high-temperature injection, control melt temperature & injection speed to avoid circuit damage, widely used for small portable medical and smart wearable control modules.
STEP, IGES, SLDPRT, X_T, CATPart, STL, 3MF solid models fully supported; native solid 3D files are recommended for accurate insert retention and mold flow stress simulation analysis.
Simple single brass insert mold: 16–24 working days including trial samples and pull-out testing; complex multi-terminal PCB insert mold with custom magnetic fixture: 30–42 working days with multi-round molding parameter adjustment and dimensional CMM inspection.
Insert Molding VS Overmolding Full Core Comparison Table
Swipe horizontally to view full columns
Comparison Dimension
Insert Molding Service
Overmolding (Two-Shot / Pick-and-Place)
Core Process Logic
Pre-placed metal/electronic inserts locked in mold, single-shot plastic encapsulation around inserts
Two sequential injection shots: first rigid plastic substrate, second soft TPE/TPU coated over substrate surface
Standard single-shot mold with custom insert locating fixture, moderate upfront tool investment
Rotary 2K dual-cavity mold or two independent molds, higher mold cost for mass production lines
Typical Industry Products
Automotive connectors, medical stainless pin housings, power tool metal shaft handles, electronics threaded insert shells
Hand tool soft grips, waterproof electronic enclosures, medical soft-touch surgical handles, automotive interior control knobs
Our Factorys
CNC Machine Shop
Established:2015
Number of Machines:500 Machines
Location:ShenZhen
Sheet Metal Factory
Established:2019
Number of Machines:150 Machines
Location:ShenZhen
Jnjection Molding Factory
Established:2018
Number of Machines:350 Machines
Location:FoShan
3D Printing Factory
Established:2015
Number of Machines:300 Machines
Location:ShenZhen
Vacuum Casting Factory
Established:2013
Number of Machines:220 Machines
Location:DongGuan
Die Casting Factory
Established:2017
Number of Machines:100 Machines
Location:ShenZhen
SUDACNC Trusted Global Partner
We are your trusted manufacturing partner. Precision Machining and Efficient Management Delivery of High-Accuracy Global Parts. We guarantee consistent quality and transparency with punctual and reliable lead times.
We are with you every step of the way, from validating a design to mass production.
30M+
Network-wide parts produced
5,000+
Companies served
5,200+
Combinations of material, process, finish
options
30+
Supply regions to mitigat e risk & enhance delivery speed
Metal and Plastic Production Solutions
SUDACNC’s digital manufacturing marketplace is your one-stop solution for production. Our team is the perfect solution for your product manufacturing needs with our staff of technical experts, ease of our secure quoting platform, and global manufacturing capacity.
SUDACNC offers competitive pricing and lead times on plastic injection molding, die casting, metal stamping, metal extrusion, plastic extrusion, sheet metal, laser cutting, waterjet cutting, laser tube cutting, and tube bending services. Start your quote or contact us today to begin.
Choose Your Optimal Price and Lead Time
The SUDACNC Instant Quoting Engine® makes it easy to upload a CAD file and compare prices and lead times in just a few clicks. With thousands of manufacturing suppliers in all 50 U.S. states and more than 20 countries, SUDACNC’s extensive network gives you options to choose the shipping timeline and price that fit your business and budget.
SUDACNC offers price matching and a 30-day price guarantee on quotes, giving you peace of mind that you’re getting the best price. When ordering prototypes — originals or models of parts that are intended exclusively for non-commercial purposes — the price shown at checkout includes tariffs. Shipping is also included, as long as your package is standard-size.
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SUDACNC Four Workflow Phases
From start to finish, our process is built for speed and clarity. Each step is transparent, keeping you in control. The result: precision results delivered on time.
Real-Time Quotes
Confirm transparent price structures, timelines, and DFM visibility in minutes, with the SUDACNC quoting engine supporting optimal strategic decisions. Upload your CAD files to reduce time spent in quoting cycles.
Quality Assurance
SUDACNC enables you to access a single, streamlined platform for managing versatile professional collaborative relationships with certified suppliers and diverse manufacturing capabilities, allowing you to scale production to meet unlimited volume requirements.
Deep Manufacturing Network
Every part of SUDACNC goes through rigorous inspection standards to ensure that we meet all your dimensional, cosmetic, and performance needs and requirements.
Industry-Focused Expertise
SUDACNC works across multiple industries, including aerospace, automotive, medical, robotics, consumer, and industrial machinery, delivering consistent quality in highly demanding projects.
All-in-One Your Reliable Manufacturing Partner
Design&Engineering Support
Rapid Prototyping
Production and Manufacturing
Quality control and distribution
Design and Engineering Support
Our work begins with understanding your design with engineering clarity. Knowing that the starting point of every successful product is understanding the engineering aspect, we work with you to comprehend design needs, analyze the specifications, and make manufacturable parts. Our early risk assessments streamline revisions, contain costs, and deal with ever-decreasing performance variability.
Practical DFM Comments to Support Design Decision Improvementss
Material Suggestions Based on Your Application
Engineering Assistance to Boost Efficiency and Longevity
Rapid Prototyping
Change concepts into real-life components fast and with ease. Rapid Precision services enable you to validate your design, test its functionality, and work out any remaining details before entering the production phase, allowing complete design confidence. Directly accompanying any design stage, fast production welcomes you to the design stage without demand to sacrifice precision.
Quick prototypes to perform experiments.
Prototypes for Form, Fit, and Function Validation
Prototyping is Perfect for Design Validation, Demonstration, and Initial Production Stages.
Production and Manufacturing
When your design is production-ready, we make the transition to production seamlessly. Supporting low, medium, and high-scale production, we maintain the same quality, repetition, and precision in each manufacturing run. Adaptable workflows allow for smooth production transitions as demand increases.
Encompassing all aspects of manufacturing
Consistency and repeatability across all ranges of production
Versatile manufacturing capabilities
Quality control and distribution
The meticulous nature of our work carries through all aspects of our business. Each component undergoes a thorough review to meet the required specifications and standards to be qualified for shipping. Following our extensive and streamlined order delivery process, we guarantee our customers receive parts that are ready to be joined and utilized for intended purpose in a timely fashion, without exception.
Quality control aligned with ISO standards
Quality documentation with complete traceability
Accurate delivery to all parts of the world
Quality Assurance & Compliance
in Every Part We Manufacture
We stay true to industry standards that have to do with quality and safety, like ISO 9001:2015 and AS9100. We assess and check every part multiple times to ensure that inspections have been done thoroughly and that we can offer no exceptions to your needs.
ISO 9001 Certified
100% Quality Inspection
Premium Material Selection
What Makes SUDACNC Different from Others
Instant Smart Quoting
Get quick pricing and DFM insights to optimize designs and reduce costs.
Global Supply Network
Access our global manufacturing network for reliable solutions of all sizes.
Certified Quality Control
Strict inspection protocols for every part. We ensure 100% accuracy and high standards.
Fast Reliable Delivery
Punctual shipping for all custom orders. Your projects always stay on schedule.
Our rich project experience accumulation and pre-analysis before production enable us to consider comprehensively and provide the mostsuitable and economical solutions, to
ISO 9001 Certified
100% Quality Inspection
Premium Material Selection
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team work close to make professionaland efficient communication with thecustomers, to save the time.
48-Hour Standard Delivery
Express 24-Hour Option
Real-Time Order Tracking
Responsible and efficient after-salesservice
We will absolutely take our responsiblityfor any potential part quality issue, andcommunicate and solve it timely to meetcustomer's demand.
Expert Technical Consultation
Custom Solution Development
Dedicated Support Specialists
What Our Clients Say
"Implementing their precision-engineered components has dramatically lowered our operational overhead. The technical support team provided exceptional guidance in tailoring the ideal setup for our specialized manufacturing floor."
— Emily Watson, Head of Manufacturing
"Faced with a sudden shortage on our main assembly line, their team expedited the critical components within a day, preventing catastrophic financial losses. Their agility and customer-first mindset make them a premier strategic partner."
— David Lin, Supply Chain Director
"The dimensional consistency of their CNC parts is flawless, which seamlessly integrated into our rigid Outgoing Quality Control protocol. We haven't had a single batch rejection since switching to their fulfillment services."
— Marcus Vance, Quality Assurance Manager
"Their end-to-end transparency and automated dispatch tracking have revolutionized how we manage our warehouse flow. It's rare to find a manufacturing vendor that pairs heavy industrial expertise with such agile digital efficiency."
— Sophia Zheng, Procurement Specialist
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