The Insert Injection Molding process provides the same setup options as Injection Molding in the Plastic Molding process group (see User Inputs for Plastic Molding). It also provides the following additional setup options:

Note that for some of the setup options provided by both Insert Injection Molding and Plastic Molding (such as Number of Small Inserts), the names and descriptions use "Insert" to mean mold insert (such as a grill insert) rather than non-molded Subcomponent.

Note also that, in the case of a part with multiple molded Subcomponents, the setup options use the term 'cavity' to refer to the mold cavity for the entire molded portion of the Assembly Molding part, rather than to the cavity for a single molded Subcomponent. So, for example, 'Number of Mold Cavities' refers to the number of top-level Insert Molding parts that are handled by the mold.

Each Insert Injection Molding machine has one of the following orientations:

Machine orientation (Horizontal or Vertical) is specified by the machine property Orientation.

By default in starting point VPEs, machine selection considers only Vertical machines. Administrators can customize the default with the cost model variable insertInjectionMoldingMachineOrientation. Users can override the default on a per-part basis with this setup option. Select one of the following:

By default in starting point VPEs, the part is removed from the mold manually. Administrators can customize the default with the cost model variable ejectMethod. Users can override the default on a part-by-part basis with this setup option. Select one of the following:

See Part Removal Time in Insert Injection Molding Formulas.

Note: Vertical machines do not support Gravity-drop part removal. If Insert Injection Molding Machine Orientation is set to Vertical, Part Eject Method must be set to Manual (the default in starting point VPEs) or Robotic; otherwise machine selection fails.

By default in starting point VPEs, Machine Selection for Insert Injection Molding considers only machines with No table. Administrators can customize the default behavior with the cost model variable verticalTableConfiguration, and specify that machine selection should consider only machines with a Shuttle table or only machines with a Rotary table, by default. With this setup option, users can override the default on a part-by-part basis.

A vertical machine has one of the following table configurations (indicated by the machine property Table Configuration):

A rotary or shuttle table allows for two molds to be processed in parallel: pick and place is performed for a part or parts made in one mold, while injection molding is performed with the other mold. Using a machine with a shuttle or rotary table can reduce cycle time and labor time—see Insert Pick and Place Operation Formulas.

Note: Horizontal machines support only the No table configuration. If you select Horizontal for Insert Injection Molding Machine Orientation, Vertical Table Configuration must be set to No table (the default in starting point VPEs); otherwise machine selection fails.

By default in starting point VPEs, for machines with a shuttle or rotary table (see Machines for Assembly Molding), tooling is assumed to include two mold lower halves and one mold upper half. This allows one lower tool to be loaded while the other (together with the tool upper half) is injected (see Formulas for Assembly Molding). Administrators can customize the default number of lower tools with the cost model variable defaultNumMoldToolsPerTable. Users can override the default on a per-part basis with this setup option. This setting drives tooling costs.

By default, the cost model assumes negligible cost for any retention tools that are required to hold non-bundled inserts in place in the mold prior to injection. In addition, the cost model assumes that a bundled insert can slide over or into its associated slide or lifter, and that no additional tool is needed to ensure that the insert is retained in place. (See Geometric Cost Drivers for Assembly Molding for information on bundled versus non-bundled inserts.)

With this setup option, users can override the default, and specify the cost for retention tools over and above the cost for slides and lifters. This cost contributes to hard tooling cost (see Tooling for Assembly Molding).