LEARNING OBJECTIVE
- To introduce participants to the concepts and applications of insert moulding and overmoulding
- To understand the materials, tooling, and machine requirements involved
- To identify key process parameters and common challenges
- To develop best practices for high-quality multi-material moulded parts
WHO SHOULD ATTEND
- Moulding Technicians and Engineers
- Tool Designers
- QA/QC Inspectors
- Technical and production supervisors
TRAINING METHODOLOGY
- Visual guides and defect charts
- Process parameter templates
- Case study materials
- Certificate of completion
COURSE OUTLINE
DAY 1: Fundamentals and Process Understanding
Morning Session: 1.0 Overview of Insert Moulding and Overmoulding
- Definitions and differences between insert moulding and overmoulding
- Applications in automotive, electronics, consumer goods
- Benefits of multi-material moulding
2.0 Materials for Insert and Overmoulding
- Compatible material combinations (metal + plastic, TPE + plastic)
- Adhesion and bonding principles
- Thermal expansion and material behavior
3.0 Tooling and Mould Design
- Mould layout for insert and overmoulding
- Gate design, parting lines, ejector considerations
- Insert retention features and alignment
Afternoon Session: 4.0 Machine and Equipment Requirements
- Vertical vs horizontal moulding machines
- Robot-assisted and manual insert placement
- Clamping, alignment and safety considerations
5.0 Insert Loading Techniques
- Manual vs automated insert placement
- Fixtures, jigs, and sensors
- Position verification and defect prevention
DAY 2: Process Optimisation and Defect Control
Morning Session: 6.0 Moulding Parameters and Process Control
- Temperature, injection speed, holding pressure
- Insert pre-heating, if required
- Controlling flash, voids, delamination
7.0 Quality Inspection for Overmoulded Parts
- Visual and dimensional checks
- Bond strength testing
- Functional testing where applicable
Afternoon Session: 8.0 Common Defects and Troubleshooting
- Insert shifting or floating
- Incomplete fill and short shots
- Poor adhesion and overmould separation
9.0 Group Exercise / Case Study
- Review sample parts and mould designs
- Identify problems and recommend solutions
- Group presentation and discussion
Wrap-Up: Lessons Learned, Final Q&A, and Action Planning
