Plastic Mouldings

Insert moulding is one of the fields we specialize in at Gilard. Using three advanced machines, we create vertical mouldings capable of increasing the insert moulding’s efficiency by several percentage points. The process of plastic injection insert moulding involves moulding of thermoplastic material around one or more pieces of insert, which is placed in a moulding cavity of plastic injection. This helps to create single, integrated and strongly bonded assembly, where the inserts or insert are covered with plastic. Metal, ceramic, another plastic or any other substance capable of withstanding plastic inject moulding process can be used for making inserts.

The process of loading custom built mould with inserts can be carried out manually or robotically.

  • Injecting molten plastic into mould
  • After it cools downs, the mould is opened to remove the components
  • Components are inspected after separating them from sprues

Various secondary operations can be included in post moulding assembly, such as:

  • Stamping die cutting in discrete circuits
  • Bonding
  • Circuit-testing
  • Micro-soldering

How insert moulding can help in improving new components?
Insert moulding is a very efficient alternative available for assembling discrete parts with soldering, fasteners, connectors or adhesives. Following reasons make it better than these methods:
1. Lower costs of labour and assembly
The labour and assembly costs get minimized as insert moulding uses thermoplastic for joining various components. For example: single stamping can be perforated for creating various circuit paths, after it is overmoulded.
2. Reduced weight and size
By removing connectors and fasteners and combining physical strength of metal and resin inserts, lighter and smaller components can be created with insert moulding.
3. Enhanced reliability
Securing every part in thermoplastic tightly, problems like part loosening, improper terminations and misalignment can be prevented by an insert moulded part. Thermoplastic resin provides enhanced resistance to vibration and shock as well.
4. Increased flexibility in design
Virtually unlimited range of configurations offered by insert moulding is what the designers appreciate the most. For example, overmoulding allows free movement of circuitry through a part in the creation of 3D circuit board.