Insert molding is the joining of two different components to create a single, integrated part. By using insert molding processes, we are able to take a metal assembly such as a wire form or stamping, and directly mold the plastic component onto the part. This is by far the most efficient and reliable way to add handles, grips, or other part features to machined or cast components.
Overmolding is a process in which one material is molded over the top of another material that has been inserted into the mold. The first material can either be inserted into the mold as a finished part (as in insert molding) or the material can be injected into the mold as the first step in the injection molding process. This is also commonly referred to as “two-shot” molding because the different materials are injected into the mold in a multi-shot process.
Our Heat Transfer process is an extremely accurate and efficient method of decorating an already molded part. During the process, a metered amount of plastic is loaded into a pot where it is held until the polymer has been melted to the specified temperature. After the material and the molds are heated, a plunger forces the material from the pot and into the mold cavities. Since the mold is also heated above the melting point of the plastic, the plastic flow of the material is unimpeded by skin effects and the molding process can be performed quickly.
K&B Molded Products offers numerous secondary assembly and finishing processes, including sonic welding. Sonic welding can be used for plastic components and assemblies for which it is not feasible to mold into a single piece. In the sonic welding process, high-frequency mechanical motion and force are applied to the joint that is to be welded. This localized motion causes friction between the two surfaces, resulting in a build-up of heat that melts the material at the desired joint. Once the vibration is removed, the material cools, leaving a solid state weld that is very strong and durable.