Insert Molding.
Unified Structural Integrity.
REBAN bridges the gap between metal precision and polymer versatility. By embedding functional inserts—from threaded bushings to complex electronic circuitry—directly into the molding cycle, we deliver hybrid components with superior pull-out strength, reduced assembly costs, and unmatched dimensional stability.
[ Automated Vertical & Horizontal Presses ] [ 0.005mm Positioning Accuracy ] [ Overmolding Specialists ]
Why Partner with REBAN?
The Strategic Advantage of Hybrid Logic
- Vertical Integration: We unify insert fabrication (CNC/Stamping) and injection molding under one protocol, eliminating multi-vendor lag and compressing lead times by 30%.
- Structural Superiority: By molding plastic directly around metal features, we create a superior mechanical lock that outperforms post-mold ultrasonic insertion in both torque and pull-out resistance.
- Component Consolidation: We eliminate secondary assembly labor and reduce total part counts by integrating functional metal components directly into the monolithic plastic architecture.
- Thermal & Material Mastery: Our expertise with high-heat polymers (PEEK, Ultem) ensures that sensitive metal inserts remain undamaged and perfectly aligned during high-pressure injection.
Insert Molding Engineering Constraints
Our technical guidelines for hybrid molding ensure optimal structural bonding and manufacturing efficiency. At REBAN, we leverage high-tonnage vertical rotary presses and sub-micron tooling to push the boundaries of part complexity and size.
| Technical Parameter | Metric Standard | Imperial Standard |
|---|---|---|
| Maximum Part Envelope | 850mm x 600mm x 250mm | 33.4 in. x 23.6 in. x 9.8 in. |
| Maximum Injection Volume | 2,800,000 mm³ | 170.8 cu. in. |
| Maximum Shot Weight | Up to 3,200g (Resin dependent) | Up to 7.05 lbs |
| Draw Depth (Max) | 150mm from parting line | 5.9 in. from parting line |
| Projected Mold Area | 250,000 mm² | 387.5 sq. in. |
| Insert Load Tolerance | ±0.02mm (Robotic Placement) | ±0.0008 in. |
Engineering Design Guidelines
- Parting Line Strategy: Our engineers design molds where the parting line passes through the center of mass whenever possible to maximize draw depth (up to 300mm / 11.8 in. total).
- Boss Wall Ratios: To prevent sink marks near metal inserts, we recommend a boss wall thickness of 0.6 to 0.7 times the nominal wall of the main part.
- Draft & Texture: A minimum draft angle of 0.5° is required for smooth vertical walls; 3°+ is suggested for parts requiring heavy Mold-Tech graining.
- Gate Placement: We utilize Sub-Gating or Valve Gating to ensure resin flow does not displace sensitive electronic inserts during high-pressure injection.
HOW TO WORK WITH US
Upload a CAD File
To start, simply select a manufacturing process and upload a 3D CAD file.
Get Quote with DFM
Within a few hours we'll send you design for manufacturability (DFM) analysis and real-time pricing.
Manufacturing Begins
Once you review your quote and place your order, we'll start the manufacturing process. We also offer finishing options.
Parts are Shipped
Our digital manufacturing process allows us to produce parts in as fast as 1 day.