{"id":6075,"date":"2025-04-14T07:56:21","date_gmt":"2025-04-14T07:56:21","guid":{"rendered":"https:\/\/4tec-engineering.com\/?p=6075"},"modified":"2025-04-23T07:18:01","modified_gmt":"2025-04-23T07:18:01","slug":"umspritzen","status":"publish","type":"post","link":"https:\/\/4tec-engineering.com\/en\/umspritzen\/","title":{"rendered":"Overmolding"},"content":{"rendered":"
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Overmolding of Metal Inserts<\/h2>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
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Shown below are two components with integrated overmolded metal inserts: on the left, a water filter for home use; on the right, a pump lever for a lawn mower. At first glance, both parts appear well-executed.\u00a0<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t

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On closer inspection, however, it's clear that the component on the left has an issue: a crack in the overmolded plastic. Under the microscope, the crack is clearly visible \u2013 but it's barely noticeable to the naked eye.\u00a0<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t

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This actually caused problems in the component mentioned above, as the filter could no longer ensure proper sealing. However, such product failures\u2014often only noticeable in the later stages of a project\u2014can be avoided through the following strategies:<\/p>

Factors affecting overmolded parts:<\/p>

Tool and Part Design<\/strong><\/p>

  • Avoid sharp edges or corners: stress concentrations can lead to cracking. All sharp transitions should therefore be rounded.<\/p><\/li>

  • Optimized wall thicknesses: large variations in wall thickness lead to uneven cooling and internal stresses within the part.<\/p><\/li>

  • Insert position: it should be as centered and symmetrical as possible to allow for stress distribution.<\/p><\/li>

  • Clearance and tolerances: the insert should not fit too tightly in the cavity. It is better to allow for slight clearance.<\/p><\/li><\/ul>

    Processing and Temperature Control<\/strong><\/p>

    • Mold temperature: if too low, it can lead to excessive shrinkage and stress cracking.<\/p><\/li>

    • Melt temperature: if too high, it can cause degradation reactions; if too low, it can result in poor adhesion.<\/p><\/li>

    • Cooling: uneven or overly rapid cooling leads to internal stresses. This increases the risk of cracking during insert placement or cooling.<\/p><\/li><\/ul>

      Insert Technology<\/strong><\/p>

      • Preheating the insert: cold metal inserts create high temperature differences, which can lead to stress cracks. \u2192 Preheat to approx. 80\u2013120\u202f\u00b0C.<\/p><\/li>

      • Surface treatment: a clean and possibly textured insert surface improves adhesion and reduces localized stresses.<\/p><\/li>

      • Decoupling through design: for particularly critical material combinations, rubber buffers, sealing lips or similar elements can serve as a buffer zone between plastic and metal.<\/p><\/li><\/ul>

        Post-Processing Stresses<\/strong><\/p>

        • Assembly forces \/ Screws: if the component is later subjected to mechanical stress (e.g. screws passing through the insert), additional stresses may promote cracking.<\/p><\/li>

        • Temperature fluctuations during operation: cyclic loading caused by differing thermal expansion between metal and plastic can lead to cyclic stresses and crack formation.<\/p><\/li><\/ul>

          Selection of Suitable Combinations<\/strong><\/p>

          • Suitable combination partners: for example, glass fiber reinforced materials often exhibit reduced shrinkage and behave more similarly to metal.<\/p><\/li>

          • Adhesion promoters: in cases of significant material differences, chemical bonding via adhesion promoters can be beneficial.<\/p><\/li>

          • Simulation: using filling simulation (Moldflow) to identify potential risk areas in advance.<\/p><\/li><\/ul>

            In our examples, material selection<\/strong> was the decisive factor: the water filter was made of ABS, while the pump lever used a glass fiber reinforced PA46-GF30. Although the reinforced material has a higher breaking strength, it also has a lower elongation at break. However, the key difference between the two materials lies in their coefficient of thermal expansion:<\/p>

            • For ABS, the coefficient of linear thermal expansion is 0.088 mm\/(m\u00b7K)<\/li>
            • For PA46-GF30, the coefficient of linear thermal expansion is 0.025 mm\/(m\u00b7K) (parallel) or 0.060 mm\/(m\u00b7K) (perpendicular).<\/li>
            • \u00a0<\/li><\/ul>

              The reinforced material exhibits lower shrinkage and is therefore subjected to less stress than the unreinforced ABS. For comparison: steel has a coefficient of linear thermal expansion of approximately 0.012 mm\/(m\u00b7K). This means that steel shrinks less than plastics and is closer to the behavior of the reinforced plastic.<\/p>

              In the component affected by stress cracking, a material change ultimately led to the desired result.\u00a0<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t<\/div>","protected":false},"excerpt":{"rendered":"

              Stress cracks, warping, or insufficient sealing \u2013 many overmolding issues only become apparent late in the development process. But they can be systematically avoided: the key lies in thoughtful design, precise process control, and the right choice of materials.<\/p>","protected":false},"author":1,"featured_media":6079,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"footnotes":""},"categories":[45],"tags":[],"class_list":["post-6075","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-konstruieren-mit-kunststoffen"],"yoast_head":"\nUmspritzen - 4Tec Engineering<\/title>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/4tec-engineering.com\/en\/umspritzen\/\" \/>\n<meta property=\"og:locale\" content=\"en_US\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"Umspritzen - 4Tec Engineering\" \/>\n<meta property=\"og:description\" content=\"Spannungsrisse, Verzug oder mangelhafte Dichtheit \u2013 viele Probleme beim Umspritzen zeigen sich erst sp\u00e4t im Entwicklungsprozess. 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