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Advantages And Differences Of Two Shot Injection Molding
There are a variety of manufacturing methods used to manufacture products that use plastic polymers, including two-shot injection molding, compression thermoset molding, and extrusion. Although all of these are viable manufacturing processes, this process has several advantages that make it the first choice of many plastic manufacturers. The process is relatively simple; inject one material into the mold to make the initial part of the product, and then inject a second material that is compatible with the raw material. Many manufacturers use this method to make plastics or polymers for three good reasons.To get more news about 2k injection molding, you can visit asm-mold.com official website.
The two-step process only requires one machine cycle, the way the initial mold is rotated and the product placed around the second mold, so that a second, compatible thermoplastic can be inserted into the second mold. Because this technology uses only one cycle, rather than a separate machine cycle, any production operation cost is lower, and fewer employees are required to manufacture the finished product while delivering more projects per run. It also ensures a firm bond between the materials without the need for further assembly down the line.
Two-shot injection molding improves the quality of most thermoplastics in the following aspects:
Improved aesthetics. When products are made of different colored plastics or polymers, they look better and are more attractive to consumers. If more than one color or texture is used, the product will look more expensive.
Improve ergonomics. Because this process allows the use of a soft-touch surface, as a result, items can have ergonomically designed handles or other parts. This is especially important for tools, medical equipment, and other hand-held items.
When silicone plastic and other rubber materials are used for gaskets and other parts that require a strong seal, it provides a better seal.
It allows you to combine the outstanding comfort and practicality of hard and soft polymers with even the smallest products.
Compared with overmolding or a more traditional insertion process, it can greatly reduce the number of dislocations.
It enables manufacturers to create more complex mold designs using multiple materials that cannot be effectively bonded by other processes.
The bond created is very strong, creating products that are more durable, more reliable, and have a longer lifespan.
Product manufacturers favor two-shot injection molding, with a wide range of applications, including automotive interior parts, medical equipment, tools, and toys. It allows manufacturers to combine various materials and colors to create final products that are both strong and attractive. Some materials can be effectively combined with this process, including silicone and thermoplastics, nylon and thermoplastic elastomers, or hard nylon and soft-touch materials.
Two-shot injection molding improves the quality of most thermoplastics in the following aspects:
Improved aesthetics. When products are made of different colored plastics or polymers, they look better and are more attractive to consumers. If more than one color or texture is used, the product will look more expensive.
Improve ergonomics. Because this process allows the use of a soft-touch surface, as a result, items can have ergonomically designed handles or other parts. This is especially important for tools, medical equipment, and other hand-held items.
When silicone plastic and other rubber materials are used for gaskets and other parts that require a strong seal, it provides a better seal.
It allows you to combine the outstanding comfort and practicality of hard and soft polymers with even the smallest products.
Compared with overmolding or a more traditional insertion process, it can greatly reduce the number of dislocations.
It enables manufacturers to create more complex mold designs using multiple materials that cannot be effectively bonded by other processes.
The bond created is very strong, creating products that are more durable, more reliable, and have a longer lifespan.
Product manufacturers favor two-shot injection molding, with a wide range of applications, including automotive interior parts, medical equipment, tools, and toys. It allows manufacturers to combine various materials and colors to create final products that are both strong and attractive. Some materials can be effectively combined with this process, including silicone and thermoplastics, nylon and thermoplastic elastomers, or hard nylon and soft-touch materials.
Tooling Innovation Provides Relief to Mask Shortages
Today many manufacturers are experiencing trying times. With the coronavirus still rampant, many shops are under siege to protect workers as directed by stay-at-home government directives and others are suffering financially while employees are forced to stay home.To get more news about 2k mold, you can visit asm-mold.com official website.
An idea came to 2K Tool Engineering Manager Kevin Smith while he watched the news and heard a request for toolmakers to develop tooling for face masks. Smith immediately saw this as an opportunity for his business to help.
Although sales for his business dropped due to the automotive focus of many of his customers, Smith is blessed with a variety of “essential” customers that are keeping his shop operational, while many other shops are closed due to Michigan’s “stay-at-home” executive order.
First, Smith found a basic CAD design for 3D printing a mask online from a 3D Printing Science Center in Montana. He then converted the file to a plastic injection application, took some of his available aluminum stock, and began to make the mold.
The lead time for this project was brisk. It took only one week to design, build, and then start mold trials. “Companies are already asking me about my design and materials,” Smith says.
There were, of course, obstacles during the design stage. The first version had the insert held in from the outside of the mask, but as the mask bent, the insert and filter fell out. “It takes trial and error to determine what set up works best. We were able to redesign the mold quickly, and the new design functions very well,” Smith says.
The mask material is a TPE, while the insert is a Polypropylene compressed-fit to hold in the Hepa filter. Smith initially had problems finding the Hepa filter material, but local furniture manufacturer Steelcase Inc. stepped in to help in the short term.
Cycle time on this mold is 30 seconds. The mold for the insert is around the same part-to-part production time frame. Smith can produce 2,000 to 3,000 masks per day. When asked if he would be producing these in different colors, he stated, “No. The masks will be available in natural only, in case medical personnel will need to see any contamination on the mask.”
Part of what helped Smith turn this project around so quickly was his new “2Gen” plastic injection molding shop located only a 5-minute drive away from 2K Tool. This shop started as a sampling facility. Many of the tools in the building are low-volume production runs for Magna, but there is open press time for trial runs.
It is businesses like 2K Tool that give people hope, highlighting how American businesses can easily convert a bad situation into potential profits.
Although sales for his business dropped due to the automotive focus of many of his customers, Smith is blessed with a variety of “essential” customers that are keeping his shop operational, while many other shops are closed due to Michigan’s “stay-at-home” executive order.
First, Smith found a basic CAD design for 3D printing a mask online from a 3D Printing Science Center in Montana. He then converted the file to a plastic injection application, took some of his available aluminum stock, and began to make the mold.
The lead time for this project was brisk. It took only one week to design, build, and then start mold trials. “Companies are already asking me about my design and materials,” Smith says.
There were, of course, obstacles during the design stage. The first version had the insert held in from the outside of the mask, but as the mask bent, the insert and filter fell out. “It takes trial and error to determine what set up works best. We were able to redesign the mold quickly, and the new design functions very well,” Smith says.
The mask material is a TPE, while the insert is a Polypropylene compressed-fit to hold in the Hepa filter. Smith initially had problems finding the Hepa filter material, but local furniture manufacturer Steelcase Inc. stepped in to help in the short term.
Cycle time on this mold is 30 seconds. The mold for the insert is around the same part-to-part production time frame. Smith can produce 2,000 to 3,000 masks per day. When asked if he would be producing these in different colors, he stated, “No. The masks will be available in natural only, in case medical personnel will need to see any contamination on the mask.”
Part of what helped Smith turn this project around so quickly was his new “2Gen” plastic injection molding shop located only a 5-minute drive away from 2K Tool. This shop started as a sampling facility. Many of the tools in the building are low-volume production runs for Magna, but there is open press time for trial runs.
It is businesses like 2K Tool that give people hope, highlighting how American businesses can easily convert a bad situation into potential profits.
2 components moulding
Two components injection moulding machines allow you to mould your part in 2 different materials at the same time. This is possible thanks to two independent injection systems.To get more news about 2k injection molding, you can visit asm-mold.com official website.
The main application for 2-K moulding is the moulding of a first rigid material and a second soft material, generally TPE i.e. Thermo plastic elastomer. These Elastomers can give flexibility to the part, or soft touch or provide a sealing against dust, spray water or tightness to fluids.
A very important aspect in the moulding of a product in 2 materials, is the adhesion of the two materials. You can rely on chemical adhesion which is inherent to the material chosen, and is improved when using index plate or rotary table moulding techniques as these allow the transfer of the 1st shot into the 2nd cavity at optimal temperature.On the other hand TPEs have technical and application limits, notably their resistance to mineral oils and hydrocarbons and temperature above 120° is poor. Vulcanised rubber is also generally superior to TPS as regards to mechanical properties especially in the low shore grades.
The 2K injection molding process is incorporated when you want the plastic parts of your product to be formed out of two materials to improve the use case and the aesthetics of the product. These 2 materials could be either of different colors or different textures thus, giving you a wide variety of options to customize your product.
The 2K injection molding process has various advantages. Some of these are listed below:
The product is more durable due to the chemical bonding.
The assembly step can be eliminated.
Products can be customized as per aesthetic requirements.
Wide variety of options available in terms of design and texture.
2K Injection molding process can be completed with one injection molding machine thus, reducing the manufacturing time.
A very important aspect in the moulding of a product in 2 materials, is the adhesion of the two materials. You can rely on chemical adhesion which is inherent to the material chosen, and is improved when using index plate or rotary table moulding techniques as these allow the transfer of the 1st shot into the 2nd cavity at optimal temperature.On the other hand TPEs have technical and application limits, notably their resistance to mineral oils and hydrocarbons and temperature above 120° is poor. Vulcanised rubber is also generally superior to TPS as regards to mechanical properties especially in the low shore grades.
The 2K injection molding process is incorporated when you want the plastic parts of your product to be formed out of two materials to improve the use case and the aesthetics of the product. These 2 materials could be either of different colors or different textures thus, giving you a wide variety of options to customize your product.
The 2K injection molding process has various advantages. Some of these are listed below:
The product is more durable due to the chemical bonding.
The assembly step can be eliminated.
Products can be customized as per aesthetic requirements.
Wide variety of options available in terms of design and texture.
2K Injection molding process can be completed with one injection molding machine thus, reducing the manufacturing time.
Injection mold manufacturing in cooperation with Knauf Automotive
Injection molding is an extremely effective technique for manufacturing car parts. Plastic parts are lightweight and durable, and with the use of the appropriate technologies, also ecological. We invite you to familiarise yourself with our specialised procedures. Check why cooperation and the substantive support of Knauf Automotive is the key to optimising injection mold design and manufacturing processes.To get more news about 2k mold, you can visit asm-mold.com official website.
1. Feasibility study & Early involvement – economical and technical care
We start the process with a feasibility study – on the basis of our knowledge, we will evaluate whether the solution is viable both from economical and technical point of view We also pay attention to the process possibilities and purposes of the given components checking whether the components require redesigning in order to be able to produce them. What's more, we give recommendation how injection moulding part design should be changed. Early in-depth economic and technical analysis leads to optimization of production as well as meeting the particular customer’s expectations.
2. Deep technical analysis of components and injection moulding process
In the next step, we prepare the technical recommendations on the parameters of the injection molded parts. Knauf Automotive's team of technologists then defines the most desirable mechanical, thermal and electrical properties of the materials. Our rheological analysis also includes the cooling and supply of each material. The aesthetic aspect is also important – plastic parts are often the key element of the design. At this stage, depending on the customer’s needs, the most appropriate material is selected.
The subject of surface decoration and use of special technologies (2K molding technology, heat/cool, IML, IMD, gas assist) are also discussed. The aesthetics of injection molded parts is an extremely complex topic.
Our specialty is the optimization for manufacturing. We know how to design for injection molding and can recommend our clients the best solution of part shape and choose proper technology even for advanced mold manufacturing. We are well aware of the importance of combining functionality and low production costs with aesthetics – this is a key issue for us.
3. Injection mold design guidelines
The final design of the injection mold is the result of in-depth analysis and communication, having taken into account previous developments. Appropriately planning the production process is extremely important – mold must be constructed in the right way so that the target element can fulfil its aesthetic function. Before making the decision to transfer the mold design to the tool shop we are able to create an appropriate prototype using 3D printers. This provides even greater assurance that a given solution will allow us to achieve perfect consistency with the project, and that the effect, i.e., the manufactured component, is one hundred percent consistent with the customer's expectations. If it is necessary to redesign a plastic part, this is performed by Knauf Automotive or an external entity. The process uses NX Siemens and CATIA software.
4. Coordination of injection mold manufacturing
After creating a satisfactory design, we provide customer support in manufacturing the injection mold. Knauf Automotive cooperates with a number of toolmakers – in Poland, Germany, Portugal, Italy and Asia. They are high-class injection mould manufacturers, selected by experts from our company. To guarantee maximum quality, each tool shop is regularly inspected. We can also cooperate with a manufacturer chosen by our client. If you decide to cooperate with a tool shop recommended by the Knauf Group, you can expect a significant reduction of production risk, short time to market and high-quality of the final product.
It is worth mentioning that despite the critical pandemic situation, we still maintain contact with Chinese toolmakers. They provide access to high-class technology at low operating costs. Our role is to make sure that the solutions developed in the Far East fully meet the production requirements and expectations of our customers.
2. Deep technical analysis of components and injection moulding process
In the next step, we prepare the technical recommendations on the parameters of the injection molded parts. Knauf Automotive's team of technologists then defines the most desirable mechanical, thermal and electrical properties of the materials. Our rheological analysis also includes the cooling and supply of each material. The aesthetic aspect is also important – plastic parts are often the key element of the design. At this stage, depending on the customer’s needs, the most appropriate material is selected.
The subject of surface decoration and use of special technologies (2K molding technology, heat/cool, IML, IMD, gas assist) are also discussed. The aesthetics of injection molded parts is an extremely complex topic.
Our specialty is the optimization for manufacturing. We know how to design for injection molding and can recommend our clients the best solution of part shape and choose proper technology even for advanced mold manufacturing. We are well aware of the importance of combining functionality and low production costs with aesthetics – this is a key issue for us.
3. Injection mold design guidelines
The final design of the injection mold is the result of in-depth analysis and communication, having taken into account previous developments. Appropriately planning the production process is extremely important – mold must be constructed in the right way so that the target element can fulfil its aesthetic function. Before making the decision to transfer the mold design to the tool shop we are able to create an appropriate prototype using 3D printers. This provides even greater assurance that a given solution will allow us to achieve perfect consistency with the project, and that the effect, i.e., the manufactured component, is one hundred percent consistent with the customer's expectations. If it is necessary to redesign a plastic part, this is performed by Knauf Automotive or an external entity. The process uses NX Siemens and CATIA software.
4. Coordination of injection mold manufacturing
After creating a satisfactory design, we provide customer support in manufacturing the injection mold. Knauf Automotive cooperates with a number of toolmakers – in Poland, Germany, Portugal, Italy and Asia. They are high-class injection mould manufacturers, selected by experts from our company. To guarantee maximum quality, each tool shop is regularly inspected. We can also cooperate with a manufacturer chosen by our client. If you decide to cooperate with a tool shop recommended by the Knauf Group, you can expect a significant reduction of production risk, short time to market and high-quality of the final product.
It is worth mentioning that despite the critical pandemic situation, we still maintain contact with Chinese toolmakers. They provide access to high-class technology at low operating costs. Our role is to make sure that the solutions developed in the Far East fully meet the production requirements and expectations of our customers.
What is 2k moulding?
2k mould means moulding two materials/colors into one plastic part. 2k moulding processes two materials with different characteristics, colors or hardness levels into one final product. 2K moulding, also known as co-injection moulding or multi-material injection moulding (MMM).To get more news about 2k injection molding, you can visit asm-mold.com official website.
2k moulding relies on special 2k mould and 2k injection moulding machine. In general, 2K injection mould have 2 cavities. In the production process, we first inject plastic into the cavity of the 2k injection mould. After hardening, the mould rotates, and then we inject plastic into another cavity to complete the 2k product. An example of 2K mouldi is a lunch box. This is a product made of hard plastic, but the lid has soft plastic edges. With 2K moulding technology, we produce complete products in two steps. It also includes bicycle handlebars, toothbrushes with soft handles, etc.
What is 2k mould?
2k mould – sometimes known as double injection or 2 shot mould – is a very innovative way to produce complicated mould parts from 2 different materials. It’s a highly meticulous, specialised and automated manufacturing process which controls the injection of multiple materials.the 2k mould is a special injection mould. Its upper mould can rotate by itself or with the help of a machine, and this mould also requires a special injection moulding machine. In addition to the corresponding changes to the injection molding machine, MingHao's 2k mould injection moulding technology is the soul of the entire technology. The mould is rotated and displaced to achieve the effect of simultaneous injection of different plastics. 2K mould have high requirements on mould accuracy and mould movements in mould manufacturing. If the processing size has a slight error, it will cause the product to be crushed during injection moulding. We have advanced high-precision processing equipment, professional project management team and perfect after-sales service system. When each 2K mould is started, the project manager will organize relevant personnel to analyze the mould's running track, cooling, and the runner system.
Application of 2k mould
Daily necessities industry, industry, electrical products industry, etc., Minghao 2k injection products are generally made of ABS, PC and other hard plastics with TPE soft plastics, such as washbasins, water buckets, toothbrush handles, mugs, two-color cups, two-color helmets, car armrests and household electrical insulation series such as power switches, mobile phone keys.
2K injection has many advantages in more complex products. It helps reduce costs, reduce assembly time, combine material properties and establish a strong connection between materials. Minghao Mould is happy to provide you with 2k injection mould solutions or help you manufacture 2k mould to produce the required 2k moulding products. Minghao will select the correct material and determine the best processing method. In this way, we can ensure that the final product fully meets or exceeds your expectations. We can help you optimize the design of 2K plastic parts and choose the best material that meets the bonding requirements of process, 2K mould design, 2K mould manufacturing and 2k injection moulding manufacturing
2k moulding relies on special 2k mould and 2k injection moulding machine. In general, 2K injection mould have 2 cavities. In the production process, we first inject plastic into the cavity of the 2k injection mould. After hardening, the mould rotates, and then we inject plastic into another cavity to complete the 2k product. An example of 2K mouldi is a lunch box. This is a product made of hard plastic, but the lid has soft plastic edges. With 2K moulding technology, we produce complete products in two steps. It also includes bicycle handlebars, toothbrushes with soft handles, etc.
What is 2k mould?
2k mould – sometimes known as double injection or 2 shot mould – is a very innovative way to produce complicated mould parts from 2 different materials. It’s a highly meticulous, specialised and automated manufacturing process which controls the injection of multiple materials.the 2k mould is a special injection mould. Its upper mould can rotate by itself or with the help of a machine, and this mould also requires a special injection moulding machine. In addition to the corresponding changes to the injection molding machine, MingHao's 2k mould injection moulding technology is the soul of the entire technology. The mould is rotated and displaced to achieve the effect of simultaneous injection of different plastics. 2K mould have high requirements on mould accuracy and mould movements in mould manufacturing. If the processing size has a slight error, it will cause the product to be crushed during injection moulding. We have advanced high-precision processing equipment, professional project management team and perfect after-sales service system. When each 2K mould is started, the project manager will organize relevant personnel to analyze the mould's running track, cooling, and the runner system.
Application of 2k mould
Daily necessities industry, industry, electrical products industry, etc., Minghao 2k injection products are generally made of ABS, PC and other hard plastics with TPE soft plastics, such as washbasins, water buckets, toothbrush handles, mugs, two-color cups, two-color helmets, car armrests and household electrical insulation series such as power switches, mobile phone keys.
2K injection has many advantages in more complex products. It helps reduce costs, reduce assembly time, combine material properties and establish a strong connection between materials. Minghao Mould is happy to provide you with 2k injection mould solutions or help you manufacture 2k mould to produce the required 2k moulding products. Minghao will select the correct material and determine the best processing method. In this way, we can ensure that the final product fully meets or exceeds your expectations. We can help you optimize the design of 2K plastic parts and choose the best material that meets the bonding requirements of process, 2K mould design, 2K mould manufacturing and 2k injection moulding manufacturing
HOW TO SOLVE THE SURFACE SAG IN 2K MOLD
The basic reason for surface sag: from the perspective of plastics, when the plastic cools and shrink, insufficient filling will lead to product surface sag or internal cavity.To get more news about 2k mold, you can visit asm-mold.com official website.
The causes and solutions of defects are different depending on the location of sag.
When the sag occurs at the final cooling position of the thick-walled product, or at a distance from the sprue:
Cause analysis: The typical thick wall and the surface sag or hole far from the sprue are usually due to the increase of effective viscosity and pressure loss, resulting in insufficient pressure in the mold cavity, resulting in insufficient pressure for filling.
Solution: Increase the feeding pressure and speed up feeding speed
When surface sag or hole appears near the sprue
Cause analysis: sag occurs near the gate, usually due to lack of gate freezing.
There are several reasons affecting gate freezing: it may be caused by the decrease of effective viscosity; In most cases, the gate does not freeze because the plastic temperature increases; High mold temperature will also affect gate freezing.
Solution: By adjusting the mold temperature, plastic temperature, increase the holding time to ensure the gate freezing.
Note: holes and bubbles are easy to confuse. Holes are sometimes mistaken for bubbles. A bubble is a gas trapped inside, and a hole is empty inside.
Jasonmould is a China mold maker of plastic molds- injection mold, die casting moulds, plastic blow molding, rotational molding, medical plastic injection molding, two shot plastic injection molding, insert molding, overmolding, metal injection molding, micro injection molding, powder injection molding, ceramic injection molding, liquid injection molding, husky injection molding, household mold, casting mold, die mold tool, custom molds, china moulds, rapid prototyping tooling, plastic prototyping tooling, punch press tooling, die and tooling for mobile/ cell phone parts, automotive parts, vacuum cleaners, rechargeable tools, telephones, copiers, computers, multimedia speakers, and many other electronic products and household appliances. And also a plastic product manufacturer, mold manufacturer China– plastic parts, plastic water tank, plastic balls, plastic containers, plastic buckle, plastic anchor, plastic hanger, plastic spoon, plastic pipe fitting, plastic tumble, plastic tableware, plastic cups, plastic bottles, plastic tray, plastic cosmetic container, plastic case, plastic food container, plastic chairs, plastic caps, plastic cap closure, plastic tubes, plastic water pipes, plastic knobs, plastic tubing, plastic utility boxes, plastic racks and so on.
When the sag occurs at the final cooling position of the thick-walled product, or at a distance from the sprue:
Cause analysis: The typical thick wall and the surface sag or hole far from the sprue are usually due to the increase of effective viscosity and pressure loss, resulting in insufficient pressure in the mold cavity, resulting in insufficient pressure for filling.
Solution: Increase the feeding pressure and speed up feeding speed
When surface sag or hole appears near the sprue
Cause analysis: sag occurs near the gate, usually due to lack of gate freezing.
There are several reasons affecting gate freezing: it may be caused by the decrease of effective viscosity; In most cases, the gate does not freeze because the plastic temperature increases; High mold temperature will also affect gate freezing.
Solution: By adjusting the mold temperature, plastic temperature, increase the holding time to ensure the gate freezing.
Note: holes and bubbles are easy to confuse. Holes are sometimes mistaken for bubbles. A bubble is a gas trapped inside, and a hole is empty inside.
Jasonmould is a China mold maker of plastic molds- injection mold, die casting moulds, plastic blow molding, rotational molding, medical plastic injection molding, two shot plastic injection molding, insert molding, overmolding, metal injection molding, micro injection molding, powder injection molding, ceramic injection molding, liquid injection molding, husky injection molding, household mold, casting mold, die mold tool, custom molds, china moulds, rapid prototyping tooling, plastic prototyping tooling, punch press tooling, die and tooling for mobile/ cell phone parts, automotive parts, vacuum cleaners, rechargeable tools, telephones, copiers, computers, multimedia speakers, and many other electronic products and household appliances. And also a plastic product manufacturer, mold manufacturer China– plastic parts, plastic water tank, plastic balls, plastic containers, plastic buckle, plastic anchor, plastic hanger, plastic spoon, plastic pipe fitting, plastic tumble, plastic tableware, plastic cups, plastic bottles, plastic tray, plastic cosmetic container, plastic case, plastic food container, plastic chairs, plastic caps, plastic cap closure, plastic tubes, plastic water pipes, plastic knobs, plastic tubing, plastic utility boxes, plastic racks and so on.