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`Am. Honda v. IV II - IPR2018-00619
`PET_HONDA_1010-0001
`
`

`

`12/31/2017
`
`What is Insert Molding for Plastic Components?
`
`About The Process
`
`The process itself is the same process used during injection molding. Solid pellets of raw
`material are melted and extruded into a mold - the plastic is then solidified - and then the press
`opens and the molded parts are ejected.
`
`Insert molding uses the same materials as the injection molding process. For extreme, high
`heat - engineered thermoplastics are used. These materials withstand very high temperatures
`and the components can withstand very harsh environments because of the physical, electrical
`and chemical properties.
`
`The insert is placed in the mold - either by hand, or by automation before the material is
`injected into the mold. Then, as the material flows into undercut features in the insert, the
`insert is anchored much more securely than if it were assembled to a previously molded
`component.
`
`Some injection molding manufacturers utilize vertical/vertical injection molding presses which
`use gravity to aid in the insert molding process by keeping the insert in position during mold
`closing.
`
`Most vertical presses have a feature that utilizes multiple bottom mold halves to be used with
`one top. While one bottom half is molding with the top half, the other bottom is available to be
`loaded with the insert.
`
`Since multiple bottom halves allow inserts to be loaded in one bottom while others are molding,
`press time is reduced.
`
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`Crescent Industries’ a custom injection molderperforms insert injection molding services. Our
`engineers can guide you through the steps of the insert molding process form designing a
`prototype, to building a build, to machining the inserts and production. Crescent offers
`precision Swiss screw machined solutions for inserts in various materials. To learn more about
`Crescent’s insert molding capabilities, please click here.
`
`Important Considerations
`
`The upfront costs for insert molding include the insert and tooling costs. Inserts need to be able
`to withstand the injection molding process because some pressures and temperatures can
`damage the inserts.
`
`There are design solutions to help shield the insert while still providing the full benefits of insert
`molding as well as finalizing the design. All of this requires experience.
`
`Developing the concept also requires a few basic considerations:
`
`. Providing some means of holding the insert during the molding process
`- Bosses or undercut features can provide additional retention strength in the molded part
`- Working with a company that provides insert molds that can determine specifically which
`components or technologies can be combined into a single component.
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`Am. Honda V. IV H - IPR2018-00619
`PET_HONDA_1010—0002
`
`2/5
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`Am. Honda v. IV II - IPR2018-00619
`PET_HONDA_1010-0002
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`Am. Honda v. IV II - IPR2018-00619
`PET_HONDA_1010-0003
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`Am. Honda v. IV II - IPR2018-00619
`PET_HONDA_1010-0004
`
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`Am. Honda v. IV II - IPR2018-00619
`PET_HONDA_1010-0005
`
`

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