PSM Mould-Form inserts are open-ended, steel inserts intended for insert molding. They provide flush threads on both sides of the plastic part, simplifying assembly and eliminating post-mold insertion steps. Their design is optimized for high mechanical performance, clean finishes, and reliable torque/pull-out resistance in both thermoplastics and thermosets.
Advantages
- Reduced cost - MOULD-FORM™ is a cold-formed steel insert, providing a cost savings of up to 50% over comparable machined inserts.
- Ease of installation - MOULD-FORM™ is simply located on a pin within the mould tool, giving a consistent flash-free insertion.
- Exceptional performance - Six large splines provide exceptional direct torque resistance. Cold formed steel achieves PC 8 strength, with PC 10 also available.
Key Features
Inserted during molding, avoiding secondary operations and reducing manufacturing steps
Six wide external splines for secure anchoring and resistance to torque during usage
No sharp corners in external geometry, minimizing radial stress and the risk of crack initiation in the plastic
Flush finish on both sides of the molded part, ensuring aesthetic quality and minimal cleanup
High pull-out and torque performance due to spline engagement and steel cores
Cold-formed design reduces cost compared to turned inserts, while eliminating metal shavings or chips during molding
Mould-Form FAQs
How is Mould-Form™ different from traditional inserts for plastics?
Traditionally, inserts for plastics have been made from brass, manufactured by metal cutting and had relatively fine knurls and undercuts. MOULD-FORM™ is steel, manufactured by cold-forming and has six large splines and a very large undercut.
What materials, strength grades, surface treatments are available?
Steel is the standard material type, aluminum and stainless steel are special material options. The standard steel type achieves PC 8 mechanical properties. Steel to PC 10 is available to special order. Zinc plating is the standard surface treatment, almost all commercially available finishes can be specified.
What are the performance benefits of Mould-Form™ ?
The six large splines give exceptional torque resistance, eliminating the risk of inserts turning. The very large undercut created by the flange and flare diameters provides excellent resistance to pushout and pull-out. Moulding-in gives a 100% plastic fill around the insert profile. The large top flange diameter provides a large contact area with the mating part, eliminating a torque induced pull-out failure.
How will Mould-Form™ reduce my cost?
Yes! TRI-STEP™ Inserts are available in a High Strength version (TST) and a Thin Walled version (TTW). The TRI-STEP™ TST is ideal for automotive & industrial applications requiring the highest strength performance. The TRI-STEP™ TTW can replace the majority of commonly used parallel and tapered inserts, including our industry standards as well as commercial equivalents. Additionally, the TTW is available in a Mini Aluminium version that is ideal for notebooks and other hand-held consumer electronics. (Mini Aluminium Insert data is available on our website.)
Are there different types of Mould-Form™?
Yes, MOULD-FORM™ can be manufactured with special diameters and lengths to suit your application. Male threaded stud types are also available. Special variants, including plain hole inserts, locating pins, ball pins and spacers can be made to order where volumes warrant a custom fastener.
What are the benefits of Mould-Form™ and moulding-in?
MOULD-FORM™ can be moulded to all types of plastic. With post moulded insertion into thermoset plastic, it is very difficult to achieve both high torque and high pull-out, MOULD-FORM™ overcomes this problem. Post moulded insertion costs can be high due to equipment cost and machine hour rate for secondary insertion. MOULD-FORM™ is designed to withstand a light compression as the mould tools close, eliminating thread damage. Cold form splines eliminate the risk of metal chips associated with knurls.
What applications would be most suited to Mould-Form™?
Most thermosetting plastic components utilise moulding-in; therefore, MOULD-FORM™ is an ideal high-strength replacement for high-cost machined inserts. It achieves a much higher performance than conventional post-moulded inserts, making it ideal for heavy-duty industrial and automotive applications. Moulding-in also eliminates handling problems associated with post-moulded insertion of large mouldings.
Mould-Form Inserts Dimensions
Product Code – (MF)
Standard Material – Steel (S)
Standard Finish – Zinc Trivalent & Clear
Sealer (W)
Special Materials – Steel PC10 (S10)
Aluminium (A) Stainless Steel (STST)
How to Specify
Design Guide
MOULD-FORM™ is designed to be moulded-in, the end face of the insert should be closed off using the faces of the mould tool or the face of a moulding pin against diameter B, if the plastic is thicker than insert length A. The performance obtained will be dependant on the type of plastic used and the localised strength of the boss and surrounding area. The suggested boss diameter should equal diameter B plus the thread size, e.g. M6 = 18.1 (12.1 +6). Smaller bosses can be used with a suggested minimum of diameter B plus (0.5 x thread size), e.g. M6 = 15.1 (12.1+(0.5 x 6).
Performance Data
The above results were obtained from PA6 GF30 bosses, moulded to the above suggested boss diameters, produced on an in-house prototype moulding machine.
** Measurement based on maximum metal condition as slight out of roundness will be present.