Insert Molded Switch Parts

Insert molding for automotive switch housings

This switch part is molded in 15% glass-filled PA66 around stamped metal terminals for an automotive switch manufacturer. The nylon gives the stiffness and heat resistance a dashboard switch needs, while the glass content stays low enough to keep a clean surface and stable dimensions around the contacts.

Insert molding is slower than ordinary molding because every shot starts with an operator or robot placing the inserts. If loading takes too long, the melt waiting in the nozzle cools down, and the next shot shows flow marks, weld lines or short shots. A good insert mold is designed around that loading step, not just around the part.

How we designed the tool

• Two cavities in AISI H13, built to the HASCO standard so the customer's maintenance team can source spare components locally.
• Insert pockets machined to tight fits, so the plastic seals against the terminals without flash that would block assembly.
• Loading fixtures that let the molder place a full set of terminals in one move, cutting loading time per cycle.
• Inserts that are easy to remove if a terminal breaks, so a damaged shot does not stop the press for long.

Quality checks on insert molded parts

Before the mold ships we run T1 samples with real terminals and check terminal position, retention and flash around every insert. A first article inspection report covers all critical dimensions. The same team that designed the mold runs the trial, so any adjustment happens in-house before you see a sample.

How a project like this works

• Tell us what you need – the mold only, molded parts, or both, and your estimated annual volume.
• Send drawings – STEP, IGES, STL, DWG or PDF, or a sample. We sign off moldability in a DFM review.
• Quotation – tooling price, part price and a schedule, with steel, cavities and runner proposed.
• Mold design approval – you approve the 3D mold design before steel is cut.
• T1 samples + FAI report – production or mold shipment starts after your approval.

Shipping molds and parts

• Molds are cleaned, rust-protected, marked and checked against a shipment checklist: cooling circuits, sprue, locating ring, ejection and support pillars.
• Molds ship with drawings, a spare-parts list and the T1 process sheet.
• Parts are packed to your packing instruction and inspected before shipment.
• We ship to customers in Europe, the USA and Asia.

After-sales

Our after-sales team supports mold maintenance and modifications remotely and can supply spare inserts. Contact [email protected].