Insert Moulding & Overmoulding
Precision insert moulding and overmoulding that combines metal components, electrical contacts and engineered plastics to create strong, accurate and fully integrated components.
Separate Parts. One Engineered Component.
Total Precision combines precision-manufactured inserts with engineering-grade plastics to produce integrated components for demanding electrical, electronic and industrial applications.
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Metal contacts, pins, leadframes and other inserts are accurately positioned within a jig, cassette or mould tool before being encapsulated in plastic. This creates a single engineered component with the required alignment, insulation, protection and mechanical performance built into the finished product.
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Customers can use insert moulding as an individual manufacturing service or combine it with Total Precision’s in-house metal pressing, assembly, forming, inspection and electrical testing capabilities.
Precision Inserts, Securely Encapsulated
Successful insert moulding depends on the accurate preparation and positioning of every component before the moulding cycle begins. Total Precision supports complex production routes involving stamped metal parts, electrical contacts, leadframes, pins and pre-assembled components.
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Existing production includes high-power connectors manufactured using three precision metal pressings produced in-house from pre-plated copper. The metalwork is loaded into cassettes and positioned within the mould tool before being overmoulded, formed, inspected and electrically tested.
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Total Precision also manufactures overmoulded leadframes and complex coil assemblies, demonstrating the ability to bring metal pressing, component preparation, moulding and quality assurance together through one accountable manufacturing partner.
High-Power
Connectors
Total Precision manufactures high-power connector components using three separate precision metal pressings produced in-house from pre-plated CuSn4 copper alloy. Progression tooling forms the required contacts before they move into the overmoulding process. The metal components are hand-loaded into dedicated cassettes, which control their position before they are placed into the mould tool. Plastic is then moulded around the metalwork to create one accurately aligned and electrically insulated connector component. Following overmoulding, the component progresses through a forming operation, 100% visual inspection and electrical testing before being placed into returnable ESD packaging.
Leadframe
Overmoulding
Total Precision produces overmoulded leadframe components using precision pressings manufactured in-house from pre-plated 1mm C101 copper. The leadframe is positioned manually within a two-impression mould tool before being encapsulated in plastic. During the mould-closing operation, the carrier section of the leadframe is cropped as part of the controlled manufacturing process. After moulding, every completed component undergoes 100% inspection and electrical Hi-Pot testing. Approved products are then placed into returnable ESD packaging, bringing metal pressing, moulding, testing and protection together within one managed production route.
Coil Assembly
Overmoulding
Complex overmoulded coil components require several preparation and assembly operations before they can enter the mould tool. The production process includes stripping the wire, wrapping it around the pins and soldering the connections. The pins are then formed to the required angle before a diode is push-fitted into position. Once the internal assembly is complete, the component is fully encapsulated using a four-cavity mould tool and 35% glass-filled nylon. This demonstrates Total Precision’s ability to combine manual preparation, electrical assembly and precision overmoulding to manufacture a single integrated component.
Electrical
Testing
Inspection and testing can be integrated into the insert moulding and overmoulding process to verify the completed product before packaging or further assembly. Depending on the component, the production route can include first-off, in-process and last-off checks, 100% visual inspection, electrical testing and Hi-Pot testing. Total Precision also has coordinate measuring capability for dimensional verification. Combining these quality checks with moulding and assembly provides greater control throughout production and helps identify potential issues before products progress into the customer’s wider manufacturing process.
Looking for an Insert Moulding & Overmoulding Partner?
Whether you require a single overmoulded component or a complete production route incorporating metal pressing, insert preparation, assembly, moulding and electrical testing, Total Precision can develop the right solution around your product.