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Home / Die Casting Technologies / Sub Assembly

Sub Assembly

A sub assembly connects small, metal components through techniques like insert molding and overmolding.

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Insert Molding
Overmolding

Why Choose

Insert Molding?Insert molding is a manufacturing process where metal components are placed into a mold before molten metal is injected around them to form a finished part. Our proprietary injected metal assembly (IMA) process is a specific type of insert molding that begins with a custom tool featuring cavities for multiple components. These components are placed into the tool, and molten zinc is injected. The zinc alloy fills the cavities, hardening to create a permanent bond between the components.

Benefits of Insert Molding and Injected Metal Assembly

  • Strengthened structure
  • Reduced Assembly
  • Complex geometries
  • Design flexibility
  • Enhanced aesthetics

Common Applications of Insert Molding

  • Electronic connectors
  • Medical devices
  • Telecommunications satellites
  • Automotive parts
  • Consumer products

Key Features Of

OvermoldingThe overmolding process creates a finished product by molding a softer or more flexible material over a rigid metal to form an end product.

Benefits

  • Reduced assembly
  • Enhanced functionality
  • Ergonomic
  • Enhanced aesthetics
  • Cost savings

Common Applications

  • Tool handles
  • Electronic device grips
  • Medical devices
  • Automotive interior components

What Is Sub Assembly?

Sub assemblies, like insert molding and overmolding, integrate components directly into molds during production to create parts with strengthened structures, reduced assembly requirements, and the ability to achieve complex designs. This streamlined approach improves production timelines and cost efficiency.

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What Is Insert Molding?

In die casting, insert molding allows for one metal component to be placed in a mold, having additional molten metal injected around the metal insert to create a finished part. This eliminates the need for secondary operations like welding, tapping, and machining.

Injected Metal Assembly (IMA) Process

This proprietary manufacturing process joins multiple components by injecting molten zinc into a mold holding the parts, creating a single, permanently bonded unit.

A woman performing a die casting sub assembly

What Is Overmolding?

Overmolding involves molding one material (often a softer or more flexible material) over another material (usually a rigid substrate) to create a finished product. This is typically used for cosmetic, texture or durability purposes.

Die cast metal part after sub assembly process

Strengthening Sub Assemblies With Insert and Overmolding

Sub-assemblies provide an efficient method for combining multiple metal parts into one integrated unit, streamlining production.

Global Reach, Local Expertise

Use our location finder to see which of our global facilities offers the processes and materials you need.

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Interested in starting your die casting journey?

Our engineers are here to answer your questions and show you how innovative die casting technologies can revolutionize your next project.

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