Design Considerations Of Core Insert Mold

The rules of Core Insert Molding are no different from those of standard injection molding. Maintain proper draft angles, keep wall thicknesses consistent, eliminate undercuts, and avoid unnecessary part features and superfine surface finishes whenever possible. This is all good advice, and applies equally to Core Insert Molding

However, that little chunk of metal does present a few additional considerations. As alluded to earlier, Protolabs hand-loads all Core Inserts. This means the operator reaches into the mold to deposit the Core Insert, and since the mold is usually quite warm, gloves must be worn. Core Inserts smaller than 0.125 in. across can be problematic, as are those too big to fit comfortably in one hand. Nor should the Core Insert location be too deep inside the mold—a 2:1 hand clearance-to-insert depth ratio is a good rule of thumb

And be aware that Protolabs may need to orientate the part differently to accommodate placement and retention of the Core Insert. The mold halves slide together horizontally, and if the Core Insert falls out during closure, damage to the mold may occur. Core Inserts should also be consistent in size—we recommend a tolerance of +/- 0.002 in. (0.05mm) on locating surfaces to avoid flashing

Finally, knit lines occur when molten plastic flows around an object and rejoins on the far side, a phenomenon that is quite possible when inserts are present. These lines are usually cosmetic, but can lead to crack formation later on. Glass-filled materials help alleviate this problem, as does beefing up the walls around these areas (within reason). Slightly thicker walls or ribs in the area around the insert are a good idea to support the insert and prevent movement

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