DOUBLE INJECTION MOLDING / TWO SHOT INJECTION (2K)

Overmolding is an injection molding process where two materials are molded together. Types of overmolding include two-shot sequential overmolding, multi-shot injection molding or insert overmolding.  Unique part designs using different materials, sections, and colors can be a time-consuming and expensive proposition. Before beginning this delicate process, a 2-shot overmolding simulation and analysis will help determine how best to design the part and specifically where the best gate location would be and how the materials will function throughout the first or second shot as well as during a multiple shot molding cycle.

 

CAE 2-shot Overmolding Analysis helps determine:

The best gate location

Optimal material flow for multiple shots

How an insert can be place for efficient molding

Two-shot sequential overmolding is where the molding machine injects the first material into a closed cavity, and then moves the mold or cores to create a second cavity, using the first component as an insert for the second shot using a different material.

Multi-shot injection molding injects multiple materials into the cavity during the same molding cycle.

Insert overmolding uses a pre-molded insert placed into the mold before injecting the second material.

 

Double Injection, sometimes known as 2 material 2 shot molding or 2K molding, is an innovative manufacturing process used to produce complicated molded parts from two different materials. Through a highly specialized and automated process we carefully control the injection of multiple materials, including two different kinds of resin, into a single, multi-chambered mold.

 

Double Injection in performed on one machine that is programmed to perform two injections in one cycle. In the first cycle, a nozzle injects plastic into a mold. The mold is then automatically rotated and a different type of plastic is injected into the mold from a second nozzle.

 

Double Injection Molding optimizes co-polymerization of hard and soft materials to create powerful molecular bond. The result is a single part with production and feature advantages. It can be used for a variety of product designs across all industries. It also allows for molding using clear plastics, colored graphics and stylish finishes which improves your product functionality and marketplace value.

 

Double Injection advantages include:

 

Lower unit cost

Improved part integrity

Multi-material efficiency

Higher-quality plastic part fabrication

Reduced handling and secondary assembly

Reduces cost and waste associated with assembly defects

Enhanced tactile and cosmetic product features