Some of the first insert molding applications were for placing threaded inserts into molded parts and encapsulating wire plug connections on electrical cords. Current custom insert molding applications are wide ranging, with few limitations on material combinations, including:
● Medical devices and instruments, such as needle hubs and tube valves
● Knobs for appliances, controls and assemblies
● Encapsulated electronic devices and electrical components
● Military equipment
● Threaded fasteners
● Encapsulated bushings, tubes, studs and posted

Plastic injection insert molding is an effective alternative to assemblies manufactured using soldering, adhesives or fasteners, with benefits including:
● Reduced assembly and labor costs (Molded as one assembly).
● Reduced size and weight (Insert molding allows for reduction of part size and weight because parts are joined with strong, light-weight plastic resin and fasteners or connectors are eliminated).
● Robotic automation in the insert molding process allows for fast and precise placement of inserts.
● Improved component reliability (Insert molding of components ensures proper alignment, prevents loosening and the plastic resin can provide improved resistance to vibration and shock).
● Improved part strength and structure (Insert molding combines the physical strength of the plastic resin and insert to produce one seamless plastic part).
● Enhanced design flexibility (Custom plastic insert molding allows for almost unlimited configurations and material combinations).
● Consolidation of components (Insert molded components enable part and inventory cost reductions).

For some, minimizing the risk of part defects while ensuring timely speed to market is a challenge. It is still common in the injection molding industry to manually perform insert molding, requiring operators to load and unload inserts into a horizontal machine. Cycle times can vary drastically from one run to the next, potentially causing variations in thermal conditions and other factors, which can lead to inconsistent insert molding outcomes. Mouette use automation technology and both horizontal and vertical machines for insert molding to help minimize human error, improve efficiencies, and ensure optimal outcomes in the injection molding process. We use automation and end-of-arm tooling to ensure that parts are always inserted correctly. Missing an insert can cause several problems, ranging from downtime or mold damage to quality issues and field failures for the customer. It is essential to have high-precision controls and processes in place to manage the insert molding operation and maximize quality — especially for meaningful and effective Design Failure Mode and Effects Analysis (DFMEA).

The expertise of operators and engineers remains crucial in an age of automation. Creativity and flexibility are often required to develop the best solutions for production challenges and achieve optimal cycle times. Methods that can be used to hold a component can range from clamps to vacuum to magnets, and selecting the most appropriate method requires expertise and experience.