MCM Composites announces its capabilities in thermoset insert molding, providing customers with components designed for strength, durability, and precision applications. The company's thermoset insert molding process produces parts that can withstand extreme conditions while maintaining cost-effectiveness and performance consistency for industries including automotive, aerospace, and electrical.

Thermoset insert molding by MCM Composites addresses many of the common challenges faced in manufacturing components subjected to high temperatures, corrosive chemicals, and mechanical stress. Traditional materials and assembly methods often fall short in these environments, leading to premature failures or costly secondary machining processes. MCM’s advanced capabilities allow for the direct molding of durable thermoset plastics around precision metal inserts, creating integrated assemblies that reduce weight and machining costs while enhancing structural integrity.

MCM's insert molding process achieves precision manufacturing through state-of-the-art injection and compression molding equipment supported by ISO 9001:2015 certification. Tight tolerances reaching ±0.0015 inches ensure that every molded part meets exact dimensional specifications, whether producing single prototypes or millions of pieces annually. This precision is critical when working with complex geometries and delicate components, where the proper bonding and positioning of inserts is essential to product performance.

MCM Composites’ manufacturing facility features an extensive range of molding presses, from 75 to 500 tons for injection molding and 50 to 800 tons for compression molding. These capabilities allow the company to accommodate small, intricate parts as well as large, heavy structural components weighing up to 50 pounds. Their injection molding technology incorporates advanced features such as degas sequences to eliminate air voids, gate cut sequences for smooth ejection without manual finishing, and core pull mechanisms for complex internal shapes. The specialized runnerless injection compression system ensures the thermoset material flows evenly around metal inserts, minimizing stress concentrations and preventing defects that can compromise long-term reliability.

Thermoset materials inherently offer high-temperature resistance and chemical stability, making them ideal for challenging environments where performance cannot be compromised. MCM’s insert molded components reliably perform at temperatures up to 260°C (500°F), maintaining strength, dimensional stability, and impact resistance under prolonged thermal and chemical exposure. This makes the components particularly suited for demanding applications such as under-the-hood automotive parts, aerospace components exposed to extreme conditions, and electrical assemblies requiring both insulation and flame retardancy.

The broad range of thermoset resins that MCM Composites offers ensures tailored solutions for diverse application requirements. Phenolic compounds provide outstanding heat resistance and electrical insulation, ideal for thermal cycling applications. Alkyd resins balance chemical resistance and aesthetic finish, suitable for components where appearance matters as well as functionality. Polyester thermosets in both bulk molding compound and sheet molding compound formats deliver excellent strength-to-weight ratios, addressing the weight reduction pressures prominent in automotive and industrial sectors. Additionally, epoxy and melamine phenolics offer superior adhesion to metal inserts and exceptional mechanical properties, while carbon fiber reinforced thermosets push performance limits by combining strength, stiffness, and lightweight benefits. Vinyl ester resins round out the portfolio, providing exceptional corrosion resistance against acids and solvents.

MCM's ability to support varying production volumes demonstrates its versatility in customer partnerships. From single-cavity molds used for prototype development and design validation to multi-cavity and family molds optimized for mass production, the company's tooling engineering team designs molds with precision and efficiency in mind. Platen sizes can accommodate small precision parts to large structural components, ensuring material use and cycle times are optimized for each project. This flexibility allows MCM Composites to carry clients through the entire product lifecycle without the need for supplier changes or process requalification.

The insert molding process at MCM integrates thorough design consultation and manufacturing planning. Engineering experts assist clients in design-for-manufacture (DFM) reviews and material selection, ensuring optimal resin and insert compatibility. Custom tooling is fabricated in-house to exact specifications with precise shut-offs and insert placement systems. Production runs benefit from automated or hand-loaded insert placement routines, supported by continuous mold maintenance to maintain consistent quality and cycle times.

Michael Fredrich, CEO of MCM Composites, emphasizes the company’s strategic focus: “Our thermoset insert molding by MCM Composites is designed to solve the toughest manufacturing challenges our customers face—from extreme temperature resilience to reducing assembly costs and improving part longevity. We combine cutting-edge technology with deep material knowledge to deliver parts that perform flawlessly in the most demanding applications.”

###

For more information about MCM Composites, contact the company here:

MCM Composites
Michael Fredrich
920-684-7800
info@mcmusa.net
1315 S. 41st St
Manitowoc, WI 54220