Plastic-metal composite parts:

Insert technology

True to our slogan MAKE IT HAPPEN, we develop ideas and implement them with our unique Intensa modular system...for your project success!

Use insert technology to integrate various mechanical and electronic functions into a multifunctional part: whether it's connector strips, housings with injected contact pins and stamped grids, switch rings or integrated power modules with bondable surfaces for electric and hybrid drives - with insert technology, you can rely on a technology that has been tried and tested in series production many times over. We can also implement multiple overmolding and parts with core pull holding pins for you!

Benefit from the expertise in the field of insert technology that Intensa has acquired in numerous projects over the decades. After the CAD development of your assembly, we at Intensa rely on the implementation in rapid prototypes according to your requirements as well as insert parts in the original material using the latest rapid tooling technologies and our master mold system for prototype injection molding.

For implementation in series production, we are at your side for small and medium quantities with our own vertical turntable machines (40T - 300T clamping force) as well as for large series with highly specialized and competitive manufacturers in our partner ecosystem.


Overmolded HV terminal and contact grid

These projects involved the development and production of an HV terminal for an electric motor (Fig. left) and a pre-molded contact grid with spring contacts for the electrical contacting of components with flat-tongue terminals (Fig. middle).

Intensa was responsible for the entire process of product development, prototype and tool production and sampling. Busbars made of 3.00 mm Cu-ETP and 0.80 mm CuCrSiTi sheet thickness are embedded in the HV terminal, the former bare and the latter galvanically nickel-plated and tin-plated.

PPA-GF30 glass fiber reinforced in UL-V0 quality was selected as the material for the overmolding due to the operating conditions, but also because of the welding and soldering temperatures in further processing.

The following modules were used here:
Want to know more about insert technology? Please contact us!
Guenther Jordan
Günter Jordan
Head of Development, Construction

Intensa Techn. Dienstleistungen GmbH

TBZ Technologiezentrum
Schlossplatz 2
A-3812 Gross Siegharts

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08:00 - 12:00 & 13:00 - 16:00


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