All from one source

Overmolding of inserts

Overmolding of inserts has become common practice and is indispensable in today’s hybrid technology. With these special processes, for example, metal parts, semi-finished parts, cable ends, magnets and much more can be overmolded with plastic.

Innovation

We take over the complete realization of your ideas - starting with the conception over the planning up to the production and overmolding of the inserts.

Flexibility

Our quick response time to special regulations and market changes allows us to optimize your production process.

Quality assurance

The quality of your overmolded inserts is ensured by individual hardware and software testing systems.

Hybrid technology for hybrid components

Components with temperature-resistant & electrically insulating shell

Overmolding of inserts is a process in injection molding technology. In this process, a prefabricated insert part is placed in the injection mold and overmolded with a plastic compound.

At B&S, we have the necessary expertise to form-fit metallic components to thermosets or thermoplastic.

This combination of plastic and inserts results in numerous hybrid components with a temperature-resistant and electrically insulating shell.

Ergonomic. Practical. Good.

Vertical injection molding machines

Our vertical injection molding machines are ideally suited for the overmolding of inserts. In contrast to the horizontal arrangement of the clamping unit widely used in injection molding, this is arranged vertically in the vertical machine.

The advantage is that the mold parting line is rotated by 90°. Handling of the inserts is simplified.

More advantages:

Ergonomics: Unhindered access to the mold during insert and remove
Automation: Shorter cycle times, higher productivity thanks to rotary table
Safety: Light barriers at the open access of the machine
Space optimization: Compact design and low space requirement

Wide range of applications

Products with inserts

As an experienced service provider in the field of insert molding, Bernhardt & Schulte offers professional solutions for your individual requirements. Our innovative and flexible processes enable us to implement your ideas and deliver customized results. With our technical know-how and many years of experience in plastic injection molding, we are the ideal partner for your next project.

Thermoplastic switch cover

with thermoset tubes

Stud

with copper contact

Balancing disc

with metall-insert

Customized hardware and software testing systems

Quality control of overmolded inserts

A company that achieves the highest standards in production must be just as ambitious when it comes to quality assurance. In order to test every mold and every assembly to the best possible standard, Bernhardt & Schulte develops devices and software for pending tests both in-house and, of course, in close cooperation with clients.

Among other things, we use a coordinate measurement machine, profile projectors, length measurement devices, pressure and traction measurements and torque measurements.

We conduct tests while production is ongoing, working with a CAQ system, with EmpBs according to the VDA, IMDS and quality molds. As requested, technical and visual tests are carried out as random checks or using 100% testing. Special workstations have been set up for this purpose on which the electrical functions can be tested.

Possible applications for overmolded inserts

Overmolded inserts for a wide range of industries

Our molded parts are of the highest quality and solve problems in various fields, including switch making, the automotive industry and the furniture industry. Wherever simple or complicated products are needed – B&S delivers.

Our continuous involvement in these industries has provided us with the necessary expertise and the right machinery for your next project.

Electrical industry

Automotive

Custom tool manufacturing

Custom plastic injection molding

Our plastic injection molding service

From prototype to production, we at Bernhardt & Schulte are the sole contact for your serial production using plastic injection molding. Our in-house mold construction enables us to intervene in production processes as quickly as possible.

Rotary switch manufacturer

Individual switching systems in line with customer requirements provide us with the opportunity to prove our capabilities in the electrical and electronics industry.

Technical molded parts

For required complex functions, B&S produces technical plastic molded parts using the injection molding process for every industrial sector.

Overmolding of inserts

With B&S injection molding technology, inserts can be reliably overmolded around complex components with thermoset or thermoplastic.

Tool and mold making

We manufacture high-quality and custom molds for your field of application. You will benefit from B&S many years of expertise.

From the idea to the series production of your
molded parts

How we process your request

1.
Your request

Send us a request for your project using the contact form on this page.

2.
Internal coordination

With the information from your request, we carry out a feasibility analysis. In doing so, we carefully check whether the project can be implemented technically, commercially and in terms of time.

3.
Offer

After a positive evaluation of the manufacturability analysis, we will prepare a mold calculation and a checklist. We will then send you the offer.

4.
Mold construction

Provided that the offer has been accepted, we start with the mold production.

5.
Production of the samples

Once the required molds have been completed, we initiate the production of the samples in close consultation.

6.
Start of serial production

As soon as quality assurance has approved the sample and it meets your expectations, we will begin the serial production.

Send us request with no obligation

Contact

Do you have questions about our services, products or processes?
We will gladly help you!

Overmolding of inserts

Innovation

Flexibility

Quality assurance

Components with temperature-resistant & electrically insulating shell

Vertical injection molding machines

Products with inserts

Thermoplastic switch cover

Stud

Balancing disc

Quality control of overmolded inserts

Overmolded inserts for a wide range of industries

Custom plastic injection molding

Our plastic injection molding service

Rotary switch manufacturer

Technical molded parts

Overmolding of inserts

Tool and mold making

1. Your request

2. Internal coordination

3. Offer

4. Mold construction

5. Production of the samples

6. Start of serial production

1.
Your request

2.
Internal coordination

3.
Offer

4.
Mold construction

5.
Production of the samples

6.
Start of serial production