Two-Shot & Insert Molding

Two-shot and insert molding are often confused, but each technology offers different benefits and applications for medical devices.

two-shot molding example

Two-shot molding highlights

  • Combines two different thermoplastics into a single molded component
  • Creates complex, multi-color, multi-material components
  • Consolidates the number of parts
  • Bonds are stronger than those from joining separate parts after molding
  • Tighter tolerances
  • Improved repeatability and accuracy
  • Uses rotary table technology, index plate systems, and core-back technology as needed
  • Expert, in-house mold building and decades of experience
  • Also known as overmolding and double-shot molding

Examples of two-shot molding

  • Instrument handles with a hard core and softer, ergonomic outer material
  • Hearing aids
  • Pacemakers and implantable cardioverter-defibrillators (ICD)
  • Cardiovascular home monitoring devices
  • Drug delivery devices
  • Abutments for dental implants
Examples of 2-shot molding
biopsy needle

Insert molding highlights

  • Plastic is molded around a pre-formed non-plastic component, often metal
  • Allows plastic and metal (or another material) to be combined into one part with plastic encapsulating the metal
  • The molded plastic can protect the inner part and then allows for sterilization
  • Creates a strong part without need of assembly

Examples of insert molding

  • Handles molded onto the metal part of hand-held devices
  • Hubs for drug delivery devices such as needles
  • Hubs for oncology devices such as those used to collect biopsies
  • Inhaler components
  • Metering pump magnets
  • Housings for pacemakers
  • Housings for endoscopy devices
Insert molded spinal device

Tegra Medical Molding Technologies

Molded frame for the sound processor in a hearing implant

Injection Molding

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Micromolding example of receiver protection for an in-ear hearing aid

Micro Molding

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Hearing aid part

Two-Shot & Insert Molding

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Injection Mold Closeup

In-House Mold Making

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