Phone: (941) 225-8209 | This email address is being protected from spambots. You need JavaScript enabled to view it.

Metal to Plastic Conversion

The demand for conversions is constantly increasing as more and more companies seek ways to reduce weight, improve efficiency, and save on cost. Delaney offers a variety of plastics, including ABS, PC, PC/ABS, PPS, PEI, Nylon, and many more.

Plastic offers several benefits that can be considered:

  • Lower weight versus machined or cast metal
  • Lower cost for complex metal to plastic conversions (reduction of several machining operations into a single molding process)
  • Corrosion is not a factor
  • Design freedom (can add radii and soft edge areas versus extra machining in metal)
  • Opportunity to integrate two materials into the same component to obtain a sealing edge or soft touch edge

The process of metal to plastic conversion starts with an assessment of the moldability of the component, followed by feedback on design changes for manufacturability (DFM) via injection molding. Once the design is updated, a Finite Element Analysis (FEA) can be performed to understand loading, stresses, and base material strength requirements.

Armed with this information, Delaney works with material suppliers to identify resins with the proper characteristics for the application. This includes an analysis of material strength, environmental exposure, chemical resistance needs, etc.

Insert Molding

Insert molding is a specialized type of injection molding that allows the inclusion of metal components in a plastic part. For example, you could have a plastic cabinet-door knob with a metal fastening screw embedded during the molding process instead of having to assemble it later.

A wide range of metal components can be used in the insert molding process, including screws, limiters, threaded fasteners, magnets, filtering screens, tubes, clips, mounting brackets, and more. These components can be made from stainless steel, brass, copper, aluminum, nickel, or bronze. Delaney will work with you to select the best combination of metal and plastic based on requirements.

Why Use Insert Molding?

There are several reasons to choose insert molding:

  1. It reduces the post-molding assembly required with separate metal elements, which can be costly. Separate installation of these components increases production time, and involves additional equipment and labor. Insert molding saves those assembly and labor costs.
  2. It enables designers to integrate features into plastic parts that will make them stronger, more durable, and more reliable.
  3. It allows enhanced product design by integrating features not possible with plastic alone: for example, a stainless-steel screen insert can provide a filtration area in a plastic part.
  4. It is useful in metal to plastic conversion to make parts more efficient. There is increasing demand across industries to produce parts in plastic instead of metal — to lower weight, reduce production costs, and eliminate corrosion. Insert molding allows retention of essential metal elements within a plastic part.

Insert molding provides the best of both worlds: it retains the strength and functionality of metal parts by embedding those elements into a more economical and efficient plastic part.

Our Process

From Invention to Bringing it to Market

So you have an idea for a great product. Congratulations! But where do you go from here? Maybe you have a prototype, or just a sketch on a napkin, and no idea what to do next. Here is the typical 'flow' of a new product or invention on it's journey to the shelves of retail stores.

  1. Drawings -  Every great invention or new product starts with an idea, some drawings, maybe a patent or two. We'll take whatever you have and create 3D CAD Drawings made and revise them as needed until they accurately depict the invention. Accurate drawings are crucial for Patent Attorneys, 3D Prototyping, Investors, Mold Builder, Manufacturing and more.
  2. Prototype - If you already have an accurate prototype or need us to make one for you, prototypes will save you time and money, allowing you to touch, feel, test, use and market your invention before manufacturing begins.
  3. Marketing or Manufacturing First (or both?) - If you're going to manufacturing first, we build molds and gear up for production. We then manufacture the product, take the finished product to market, and product is ready to ship to buyers.

    If you are doing Marketing first, you can begin marketing your drawings and prototype, get commitments from investors, buyers and distributors. Then we start building molds, gearing up and manufacturing.

    Want to do both? We will build the molds and gear up simultaneously with marketing your prototype or drawings.

It's that easy with Delaney. See our easy to understand flowchart for reference and visit our Inventor's FAQ. Contact us at (941) 225-8209 or This email address is being protected from spambots. You need JavaScript enabled to view it.

inventors flowchart

This is our 130 ton plastic injection molding machine making parts for use in water heaters. It shows the robot removing the sprue and runners and dropping them into a barrel for recycling.

This is a 16 cavity, four-drop hot runner mold. We make 200,000 of these parts every month for one customer.

Our 250 Ton Molding machine is producing components for a product used in the marine industry.

The resin is 33% fiberglass-filled Nylon 66. The wall thickness and reinforcing ribs make this part very robust and capable of performing well in the demanding environment in which it will be used.

The mold is built from H-13 tool-steel and is a single cavity design. Multiple brass insert have been over-molded into the component which provide metal threads for the assembly bolts.


COMPLETE PRODUCT DEVELOPMENT

We can help you take your project every step of the way, from concept to shipping the finished product to Distributors. Use us for every step, or just the ones you need help with.

  • 3-D CAD DRAWINGS Drawn for the Injection Molding process
  • PROTOTYPING Rapid Prototyping in days, not weeks
  • MANUFACTURING Short runs or high volume
  • ASSEMBLY Component and Product Assembly
  • PACKAGING For the retail or wholesale market
  • SHIPPING Directly to your distribution center

We have a network of resources in the following fields:

  • GRAPHIC DESIGN
  • PACKAGING DESIGN
  • VIDEO PRODUCTION
  • PRODUCT BRANDING
  • COMPUTER ANIMATION
  • PATENTS AND TRADEMARKS
  • PRODUCT TESTING AND CERTIFICATION

RENDERINGS

                                          PHOTO-REALISTIC STILL RENDERINGS AND ANIMATIONS

Using your CAD Drawings, we can create stunning three dimensional images of your product. Still renderings are great for print media, advertising, and more.

Photo-realistic animations really bring your product to life! They are useful in marketing your new product, attracting investors, licensees, or buyers.

An animation can demonstrate exactly how your product works, what it does, and showcase all its benefits.

 

 

Plastic Injection Molding

Delaney Manufacturing manufactures a wide range of plastic components and parts for Industrial, Medical, Military, and Consumer Products.

No minimums or maximums, from millions of parts, or ten parts, we work to supply our customers with what they need.

Assembled parts, packaged products for the retail market, and can even ship your finished product in bulk directly to your distributors or retail outlets!

Professional CAD Design | Prototypes | Product Assembly | Retail Packaging

                                                                                 Contact us at (941) 225-8209 or This email address is being protected from spambots. You need JavaScript enabled to view it.

About

About Delaney Manufacturing

The principles of Delaney Manufacturing have over 35 years experience in plastic manufactuing. We provide a quality product and superior customer service. We are committed to making each step of the process as smooth as possible, and regard our customers as partners. We work hard to achieve common goals.

We have a broad range of experience in Plastic Injection Molding. From consumer goods, medical applications, military products, and components for other manufacturers.

Our overall efficiency in machine cycle times, scrap reduction, plant scheduling, and in secondary operations enables us to be very competitive in the industry.

Delaney Manufacturing manufactures a wide range of plastic components and parts for Industrial, Medical, Military, and Consumer Products.

No minimums or maximums, from millions of parts, or ten parts, we work to supply our customers with what they need.

Assembled parts, packaged products for the retail market, and can even ship your finished product in bulk directly to your distributors or retail outlets!

Professional CAD Design | Prototypes | Product Assembly | Retail Packaging