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10 Things You Need To Know About 2K Injection Moulding

2K Injection Moulding

Injection moulding is a complex process, with many different types of moulds and manufacturing processes involved. There are also many variations on the general principles which can make it difficult to understand for those new to the field. It’s no wonder that so many people find injection moulding intimidating! To make things easier, we’ve compiled a list of ten important things you need to know about injection moulding. If you work in the manufacturing industry or are hoping to break into it as a career, this article will give you some insight into one of the most commonly-used methods of creating new products from raw materials. Whether you’re thinking about getting into injection moulding as an employee or contractor, or just want to understand more about the process so you can get a job interview, read on to learn more!

What is 2K Injection Moulding?

2K Injection moulding is a process that creates a new product by injecting molten liquid into a mould. The molten liquid is usually created by a heated screw, which is where the “2K” comes from. This process is used to create a wide range of products, from consumer goods like toys or appliances, to industrial parts used in large-scale equipment and infrastructure. Because it’s such a general method of manufacturing, there are many different variations of the 2K process. Some of these are: – 2K single-stage – a single injection cycle followed by a single extraction cycle – 2K sequential – injecting molten liquid into the mould and allowing it to cool before the next phase begins – 2K transfer moulding – injecting molten liquid into one mould, transferring it to another, and then expelling it from the second mould.

Why Use 2K Injection Moulding?

There are many reasons why someone would choose to use 2K injection moulding. A few of the most common ones are: – Speed – injection moulding can be much faster than manual labour, or other methods of production. Some types of products can be produced in large quantities in a matter of hours instead of days or weeks. – Consistency – there are many processes that lead to inconsistent results, but injection moulding is generally very consistent. Products that are created by different methods may not fit together the way they should, or may not be as durable. – Economy – injection moulding is one of the most cost-effective methods of production available. The high volume of product that can be produced by some machines also leads to very affordable pricing. – Quality – the design of the mould and how it’s made will determine the quality of the finished product. While there are other methods that can produce higher quality products, injection moulding can achieve a wide range of quality levels.

The Different Types of Moulds in 2K Injection Moulding

There are many different mould types in 2K injection moulding. The most common are: – Standard – a simple, single cavity, open-ended mould. – Closed-end – a simple, single cavity mould with a closed end. – Open-end – a simple, single cavity, open-ended mould. – Loose-end – a simple, single cavity, open-ended mould with an unconnected tie bar. – Tight-end – a simple, single cavity, close-ended mould with a connected tie bar. The tie bar will be connected to the injected material.

2K Resin Selection

The type of resin you use will depend on the finished product you want to create. When choosing a resin for your 2K injection moulding job, you’ll first want to select the type. There are three main types: Thermoset, thermoplastic, and high-pressure thermoset (HPT). Depending on the desired application, you may want to choose a type of resin with different physical properties. These include: – Hardness – how easy it is to scratch or dent – Tear strength – how easy it is to tear the material – Impact strength – how well it can resist breaking from a shock – Coefficient of friction – how easily it grips to other materials – Electrical conductivity – how easily electricity passes through the material – Flammability – how easy it is to catch fire – Gas permeability – how easily gases, such as oxygen, carbon dioxide, and water vapour, pass through the material.

Don’t Forget The Other Parts!

In addition to the resin you use, there are a few other parts that are important to the mould. These include: – Runner – the path that the molten material takes through the mould. – Cavity – the open space where the finished product will be formed. – Sprue – a pathway for pouring the resin into the cavity. – Flow taps – where the resin comes into contact with the mould and begins to cool.

Limiting Factors in 2K Injection Moulding

In any manufacturing method, there are always limiting factors that one must take into account. When creating a mould, you must consider the following factors: – Material – the material used to make the mould must be able to withstand the temperatures of the molten material without deforming. – Size – mould size will depend on the product you’re creating, but size has an impact on the amount of time required to create the mould. – Design – the design of the mould will determine the quality of the finished product. – Runner system – the type of runner system you use will depend on the type of material you’re using.

Where to Learn More

Injection moulding is a complex process that can seem intimidating to those unfamiliar with it. Luckily, there are lots of resources to help demystify it and make it easier to understand. This article has given you some important information to get started with, so you can better understand 2K injection moulding and the role it plays in the manufacturing process. To learn more, you can also read through the resources listed below.


What Is Injection Molding? 5 Unknown Facts

What is injection molding?
Injection molding is a process in which thin-walled parts are made of non-ferrous metals, plastics, and steel using automated equipment. This technology characterizes by high performance. When creating parts, a liquid melt obtained from these materials is fed at high speed into a special mold, after which casting of a given configuration obtains under pressure.

Features of metal injection molding technology

This device is casting equipment, the design of which provides for movable and fixed parts. The first move along with the guide cylinders and the second is mounted on a stationary plate.

What is injection molding?  Before the start of the technological process, the movable part of the mold was tightly fixed to the fixed parts with the help of a hydraulic cylinder. Then, to prevent the movement of these parts, the latter fastens with special locks.

After pouring and solidifying the molten material, the movable part of the device shifts to the side, and the workpiece obtained under high pressure removes from the equipment using mechanical pushers.

This composition is used to eliminate the negative impact of high temperatures on the steel parts of the equipment.

What is injection molding?

The main unit of this equipment is the chamber in which the material presses. This structural element is of two types: cold and hot. Structurally, the first chamber presents in the form of a horizontally laid cylinder, inside of which there is a funnel piston used for pouring the molten material.

Moreover, the process of manufacturing parts in such equipment is as follows: after filling the installation with metal, a piston starts, which, moving inside the cylinder, pumps the melt into the mold. After filling the latter, the pressure inside the chamber increases. This happens by increasing the force on the piston, which leads to the crystallization of the metal.

The function of Hot Chambers In Injection molding

What is injection molding? The hot chamber of the molds presents in the form of a bath located in a cast-iron crucible, which constantly heats during the creation of blanks. In such installations, a piston is also used, which pushes the melt out of the crucible while moving.

Further, the metal rises through a special channel with a heated mouthpiece (which prevents the solidification of the material), through which it enters the mold. At the end of the process, the remains of the melt return to the bath.

Moreover, hot chamber molds are used to create blanks from zinc and magnesium alloys.

What is injection molding? Material heating temperature

The temperature to which the material heats and is selected considers two parameters. The grade of the alloy and the geometric parameters of the part create. Failure to comply with this rule leads to serious consequences.

Moreover, due to overheating of the material during mold pouring, splashes fly out that block the ventilation holes, as a result of which gas removal disturbs, which leads to the appearance of pores in the workpiece after the latter has hardened.

Exceeding temperature increases the duration of metal crystallization

Exceeding the permissible temperature leads to an increase in the duration of metal crystallization, this is why it takes more time to complete the process.

What is injection molding? This leads to an increase in the load on the equipment, which increases the wear of the mold. In such conditions, the risks of welding metal to the inner walls increase. As a result, the probability of damage to the part during ejection increases.

Moreover, this technological process involves pressing at a minimum temperature. Non-ferrous metals heat 10-300 degrees above the point at which the alloy begins to solidify.

At the same time, if the technical task requires the manufacture of parts with a thin wall, the heating temperature increases. When creating castings of a simple configuration, the opposite approach uses. In such cases, the material heats to a temperature slightly above the melting point.

Manufacturing of high-strength parts

If high-strength parts are manufactured during this technological process, then the metal pours into the mold in a solid-liquid state. This approach achieves the following results:

  • Eliminate the appearance of a shrinkage effect in the created workpiece;
  • Reduce the negative impact of high temperature on equipment;
  • Reduce the duration of the casting hardening process;
  • Reduce the risks of welding metal to the inner walls.

Moreover, metal with hard phase inclusions is pressed exclusively in cold chamber machines. This explains by the fact that when manufacturing parts from this material in other equipment. What is injection molding? Then the risks of melt solidification in the supply channel increase.

In particular, during aluminum injection molding, the volume of solids should be 40-60%, providing that the molds are easily filled and the quality of the casting remains at a high level.

Molten material feed rate

The speed at which the piston compresses the molten material determines by taking into account the characteristics of the alloy and the geometry of the part to manufacture:

Detail of a complex geometric shape and with thin walls. When creating such a workpiece, the melt should be pressed at high speed. This requirement explains by the fact that the liquid material must have time to fill all the cavities before solidification begins.

Moreover, exceeding the permissible pressing speed leads to the fact that the supplied jet scatters into small drops, as a result of which air enters the melt. If the design provides for an insufficient number of channels intended for the removal of gases, or they clog, voids will remain in the cast billet.

In order to avoid such consequences, injection molding carries out in a vacuum in which the mold is placed.

The speed determines the quality of the casting

The speed at which the pressing carries out determines the quality of the castings and the life of the equipment. If the melt is fed too quickly, then because of this, the lubricant that the bath has been treated with is washed off. Because of this, the metal sticks to the inner walls, which, when pushed out, leads to damage to the workpiece.

If the speed is too slow, the quality of the part deteriorates. In this case, the metal begins to solidify before the pressure inside the equipment increases. A smaller parameter selects when creating blanks from steel and copper alloys. Molten tin and zinc fed at a faster rate.

Pressure on the melt during solidification

After filling the mold with metal, the pressure on the piston increases many times. The material experiences such an impact until it hardens. Through pressure:

  • The density of the workpiece increases;
  • Improved mechanical characteristics of the casting;
  • The formation of shrinkage defects excludes;
  • The quality of the casting improves;
  • The risk of marriage reduces;
  • The surface finish of the metal part increases.

What Are the Advantages of Injection Molding?

What is Injection molding?

What are the advantages of injection molding? The essence of this method lies in the fact that the molten metal is fed into a steel split mold under pressure. The working pressure on the melt is carried out directly by compressed air (gas) or by a piston, which moves under the action of compressed air (gas), emulsion, or oil.

The pressure can reach several hundred atmospheres, which ensures good filling of the mold and the production of castings of the 3-5th accuracy class and with a surface roughness corresponding to the 5-8th class. This provides great performance.

Injection molding is carried out on compressor and piston machines. Piston machines are made with vertical and horizontal pressing chambers. Chambers can be cold or hot.

The scheme of injection molding on a machine with a vertical chamber is as follows. Melt 2 is poured with a measuring spoon into the pressing chamber 3.

Moreover, the upper piston 1, descending, exerts great pressure on a portion of the melt, which transfers pressure to the lower piston 8. The piston, moving, open the gate channel 11, through which the melt fills the mold cavity.

The procedure of molding machine

a – with a cold vertical pressing chamber,

b – with a cold horizontal pressing chamber;

c – position before pouring,

d – during pouring,

e – after pouring

Moreover, the mold consists of two half-molds 4 and 5. After the melt solidifies, the half-mold 4 moves aside, and the casting 7 together with the sprue 10 pushes out by pushers 6. Excess metal 9, which has not entered the mold cavity, pushes out of the chamber by piston 8 and goes to the smelter.

Injection molding on a machine with horizontal chamber proceeds in the same sequence.

What are the advantages of injection molding?

Injection molding allows you to solve one of the most important tasks of foundry production: to bring the dimensions of the casting as close as possible to the dimensions of the finished part.

Moreover, castings obtained in metal molds have a clean and smooth surface, which significantly reduces the surface finish of parts (grinding, polishing, etc.). This method uses to cast critical parts with thin walls and complex configurations.

In addition, injection molding is used to connect several parts or to obtain castings with fittings from other metals. Castings obtained by injection molding have a fine-grained structure and high mechanical properties.

The most advanced methods for manufacturing castings

What are the advantages of injection molding? It is also economically advantageous that a large number of castings can produce in a single mold in a short time. The high productivity of this casting method and the minimum allowances reduce the cost of production both in the foundry and in the machine shops.

In addition, injection molding eliminates the use of sand, so sanitary production conditions are better than in conventional foundries.

Moreover, on the other hand, injection molding is a complex technological process that requires knowledge of alloy metallurgy, casting technology, special knowledge of tool production in the manufacture of molds, and, finally, mechanics in the operation of injection molding machines.

Injection molding has some drawbacks

Injection molding has some drawbacks, such as the appearance of small air pockets (porosity) in castings. The air in the cavity of the mold does not have time to completely go out and partially mixes with the melt.

The gases dissolved in the metal do not have time to leave the casting; due to the porosity of the casting, it is impossible to heat treat it, since swellings appear when heated. Moreover, it is difficult, and sometimes impossible, to cast a part with an undercut and internal cavity in this way.

The machines and molds that exist in modern production are suitable only for the manufacture of castings from alloys with a melting point below 1000 ° C. Special experimental casting machines and molds have been made for casting steel.

Die casting can produce castings, not from all alloys

The most suitable are zinc alloys, some aluminum, and brass. Moreover, it is more difficult to obtain parts from steel and cast iron in this way. Bronze parts are not cast under pressure.

The high cost of equipment and molds makes it not always profitable to produce small batches of castings by injection molding, so the injection molding method is widely used in serial and mass production.

The 6 advantages of plastic injection molding

Injection molding allows the production of large quantities of plastic products and components in a short time. Moreover, it guarantees the dimensional repeatability of the pieces and reduces production costs thanks to the automation of the production process.

What are the advantages of injection molding? The molding of plastic materials is one of the most widespread techniques in the transformation processes of plastic materials.

It is a procedure whereby the techno plastic material melts and injects at high pressure inside the closed molds. It opens once the material has solidified and the product is ready.

Moreover, the wide diffusion of this technique can explain by its important advantages. It brings in terms of production efficiency and cost reduction.

But that’s not all: there are numerous other advantages of plastic injection molding that make this technique a viable solution for the production of plastic components.

It is precisely for this reason that we use injection molding of plastic materials to provide its customers with quality products that best meet the needs of various companies.

The 6 advantages of plastic injection molding.

Injection molding of plastic materials means obtaining large quantities of products in a short time. Moreover, this advantage accompanies by the consequent possibility of reducing production costs. Thanks to the automation of the entire procedure.

Production of complex design components

The versatility of injection molding involves, among other advantages. The possibility of obtaining parts with complex geometries is impossible to obtain with different techniques. In this way, injection molding makes it possible to respond to any need, making possible a high degree of customization of the products.

Moreover, the experience and competence of the supplier certainly contribute to this advantage.

The strength and stability of the pieces produced

Thanks to their stability, the plastic components have excellent durability over time. Thus, contributing to the quality of the final product itself.