Company insight
When plastic meets metal at the micron level
Recognising that OEMs need to combine electrical, mechanical and structural functions within exceptionally small components, Accumold’s micro insert moulding programmes integrate multiple functions without compromising reliability or manufacturability.
edical devices are becoming more capable, compact and integrated. Functions once distributed across plastic housings, metal conductors, bonded electrodes, sensors and connectors are increasingly consolidated into single, highly engineered components. This shift towards fewer parts, tighter packaging and greater functional density is driving increased interest in micro insert moulding. At Accumold, this trend is evident across a growing range of medical programmes where original equipment manufacturers (OEMs) need to combine electrical, mechanical and structural functions within exceptionally small components. The challenge is not simply making parts smaller. It is integrating multiple functions without compromising reliability or manufacturability.
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Managing the material interface Metals and polymers respond differently to manufacturing and environmental conditions. Metals conduct heat quickly, while polymers generally do not. They also expand and contract at different rates. Polymers may absorb moisture, creep or relax, while metal inserts tend to remain more dimensionally stable. Insert cleanliness, plating, oxidation, moulding pressure and temperature can all influence how effectively the polymer seals around the metal.
Reliable production begins with insert handling. Thin lead frames, miniature electrodes, plated contacts, micro meshes and wire-like structures can bend, shift or become contaminated before moulding begins. A repeatable process must protect
“The challenge is not simply moulding a successful part once; it is maintaining insert position across cavities, production lots and long manufacturing runs.”
Micro insert moulding integrates metal elements directly into moulded polymer geometries. Electrodes, contacts, lead frames and reinforcing components can become part of a single moulded component, reducing assembly steps and bonded joints while improving alignment repeatability. The technology also enables compact designs that may be difficult to achieve through conventional assembly. However, the polymer-metal interface is often where product reliability is determined. An incomplete seal around an insert can create leakage paths, corrosion risks or contamination concerns. A positional shift of only a few microns may affect signal fidelity or repeatability. Residual stress at the interface can also lead to creep or relaxation that changes fit and performance over time. In medical applications, these issues may have regulatory and patient-safety implications.
www.medicaldevice-developments.com
insert condition, control cleanliness, locate each insert accurately and keep it stable throughout injection.
Accumold has developed production- proven processes for handling delicate micro-scale inserts while maintaining positional accuracy and repeatability in high-volume manufacturing environments. Geometry is equally important. Mechanical capture features, pockets, locking geometries, controlled shutoffs and strain-relief zones can help distribute stress and improve sealing. These features must support more than initial strength because medical components may experience sterilisation, thermal cycling, repeated actuation, fluid exposure or long-term storage. In Accumold’s experience, the best outcomes occur when micro moulding expertise is engaged early enough to influence interface design before critical features are finalised.
Material, position and measurement Polymer selection must account for long- term interface performance. Creep, stress relaxation, thermal mismatch, chemical exposure and sterilisation can alter material properties or micron-scale fits. High-performance materials such as LCP, PEI and PEEK may provide the required stiffness, thermal stability or chemical resistance, but they also require disciplined processing control. Positional tolerance is especially critical in electrode and sensor applications. Small shifts can influence electrical contact, calibration, assembly fit, sealing and mechanical performance. The challenge is not simply moulding a successful part once; it is maintaining insert position across cavities, production lots and long manufacturing runs. Accumold’s high- volume micro moulding experience demonstrates that scalable manufacturing depends on maintaining this level of positional control consistently over time. Inspection must verify insert position and orientation while detecting flash, incomplete sealing and interface instability. Measurement systems must also distinguish actual part variation from metrology variation. For medical applications, passing an initial drawing is not enough. The process must remain stable, measurable and predictable. Micro insert moulding offers medical device teams a powerful path to miniaturisation and functional integration. Success depends on predictable insert handling, intentional interface design, repeatable positional control and rigorous validation.
At Accumold, we have found that successful micro insert moulding programmes are built on engineering discipline, manufacturing consistency and validation rigour from the earliest stages of development. When plastic meets metal at the micron level, engineered reliability is what transforms a promising concept into a medical component that can be trusted at scale. ●
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