Introduction

Our lives are filled with plastic products. Even things that are made up of other materials like metals also have plastic parts in them, like the handle of your bicycle. Have you ever wondered how these plastic pieces in the everyday things in our life are made? There are many different types of plastic products. Some are single-colored, some are dual-colored and others are multi-colored. Most of the dual-colored plastic pieces are made from a technique called the 2K mould technique.

To some people, it might seem a bit complicated, but in fact, it’s very simple. The 2K mould technique is also commonly known as the 2-shot injection molding process. As the name suggests, it is a process involving a mold and the plastic which is injected into the mold.

What is the 2K mould technique?

The 2K mould technique, also known as the 2K injection molding process, is a manufacturing process. The 2K mould manufacturing process is used to manufacture molded plastic products that are made up of two different materials combined together or two different colors of the same material combined together to form a single product.

The mold used for this process is the two-part mold, which means that the mold has two parts. The two materials, same or different, are chemically bonded when the two are merged together to form 1 single product.

The process of 2k mould technique

2k mould Injection molding process is one of the most primary molding methods for thermoplastic materials. The process usually includes the steps; plasticization, 1^st injection, rotation, 2^nd injection, cooling, and ejection.

The plastic materials or plastic pallets are introduced in the barrels where they are compressed with the help of the rotating screw that is inside the barrel.

As this is a 2k molding process, there will be 2 types of plastic materials, which will be introduced in 2 different barrels. The heating bands wrapped around the rotating screw further help the rotating screw to warm up the plastic. As the plastic pallets are moved forward along the barrel by the rotating screw, they are gradually melted. The plastic is entirely melted when it reaches the frontal end of the Barrel.

When enough melted plastic is in front of the rotating screw end, the rotating screw moves forward, injecting the melted plastic into the mold cavity. When the melted plastic starts shrinking inside the mold due to cooling, the screw keeps injecting the molten plastic into the mold cavity continuously, for replenishment to ensure that a completed structured product is produced.

This is the first injection. The temperature controller introduces cooling water or oil into the mold, near the mold cavity to maintain the specified mold temperature to help solidify the molten plastic inside the mold.  The molten plastic cools down and solidifies in less than a minute.

After it solidifies, the mold opens and the whole part of the mold with the solidified plastic rotates 180-degree. Then the mold closes again, and the second molted plastic is injected into the rotating mold. It then solidifies, the ejector rod moves the ejector pins forward and forces the molded solidified plastic out of the mold cavity.

The importance of the 2K mould technique

There are many benefits that come from the 2K mould technique, which makes the process important.

Best for making products of 2 different material/color

The 2K mould technique is a very useful technique. it is one of the most used processes to manufacture dual-colored plastic products. And not just dual-colored plastic products but also plastic products that consist of two different plastic materials.

For example, the bicycle handle has a harder plastic body but the place is where you put your finger has a softer plastic. Likewise, yeah toothbrush has a Harder plastic body but where you place your fingers is a softer plastic.

Versatile

The 2K mould technique is a very versatile process. We can use this process to produce multiple different types of products. we can use different molds to produce different products.

We can also use different types of plastic materials as well. This process is used in many different types of product manufacturing industries. There are so many products that have a 2K mould process.

Less time consuming

No secondary process is required in the manufacturing of the products. everything happens in the machine. the whole double injection process of 2k mould happens in the machine, in seconds or a minute the product is ready.

Attractive and precise appearance of the product

The 2K mold technique Is a very precise technique. The products produced from this technique are also more aesthetically good-looking.

This is a very efficient technique to combine two different types of plastics for example a harder (substrate part) and a softer plastic (over-molded part) together with precision. The two plastic pieces fit so perfectly together, it feels like they are meant for each other.

Extremely cost-effective

I’m not going to skip over the fact that the 2K mold technique is a very cost-effective process for producing bulk amounts of plastic products at a very reasonable price easily. This is a very great option as the only cost is the initial cost for the machine. Once you have the machine it’s very easy and cheap to produce huge masses of Plastic products with this.

Beautiful, multi-colored plastic products can be manufactured with the help of the 2k mold technique. There is no need for painting no extra secondary process is needed for completing the process of product manufacturing. It’s a very simple easy a quick process that manufacturers plastic products. the cost per piece is also very low. therefore, it is. An ideal process for manufacturing plastic products. many manufacturers preferred this process because of the amazing advantages it offers.

 

What are the Advantages that a 2-shot Mold Supplier Enjoys?

Two-shot injection molding is one of many manufacturing techniques used to make items out of plastic polymers. When it comes down to production, one method finishes above the others: 2-shot mold supplier!

Many processes like compression thermoset molding and extrusion can produce the finished product. However, this process provides an edge with its advantages when considering alternatives such as flexibility or lower cost because there are fewer pieces needed for each part which means less waste material where you only need half a tool instead of just storing them away uselessly after use, unlike other techniques that require inventories full at all times.

What Is Two-Shot Injection Molding?

Two-shot injection molding is a type of continuous process plastic manufacturing that uses two different types of resin in one shot to produce parts.

In recent years, this technique has become the standard for product development and production because it offers many advantages over simpler methods such as; reduced costs due in part to using materials more efficiently (less waste), faster cycle times which allow manufacturers greater responsiveness with designs changes on products while still meeting customer demand levels, etc.

A 2-shot mold supplier can enjoy many advantages. The main advantage that a 2-shot mold supplier has is their ability to produce hundreds or even thousands of different products with just one set. They are also able to create complex shapes quickly and efficiently using these molds, which means they don’t have as much invested in equipment like extruders, ovens, etc., saving money on operational costs over time!

Here Are A Few Examples of How Two-Shot Injection Molding May Help Distinguish Products While Also Enhancing Advantages.

Examples

A 2-shot mold supplier offers many advantages. For example, they can produce more parts with less time and money as well as offer higher quality products due to better surface finishes than companies who use conventional injection methods or even lost wax casting techniques such these things are common among 3D printing technologies used by some commercial prototypes in their quest for innovation.

It’s Easy to Do Two-Shot Injection Molding

Injection molding is a process where one material gets injected into another in order to make the initial sections of your product. Then, if you want colour or additional parts added on there too then they are done by just one injection for both materials rather!

Do You Want to Make Your Own Product?

Injection molding is a great way for beginners! It’s easy and quick. The process basically goes like this. First, the material of choice gets injected into an empty cavity made from another machine. This has already been designed with specific cavities on its part just waiting patiently for new items to be added to their general area.

Then if we need color or extra pieces too they’re done easily as one single operation. You would not need other steps involved at all because these two processes happen simultaneously. So no need to waste time separating parts when there are only seconds left before closing up shop.

Two-Shot Injection Molding Saves Money, Improves Quality, And Reduces Labor

Two-Shot Injection Molding is a great way to save money. You can produce two identical parts in one process. This means your company is able to replace any broken equipment or make repairs more quickly than if you are using traditional instruction of manufacturing!

Two-Shot Injection molding is a new technology that improves product quality and consistency. It provides the best of both worlds. It tends to provide better stiffness for large parts as well as produce finer details like circuit boards or circuits. Also, it produces all this with one passage through the machine instead of two separate passes over it to create each part.”

Two-Shot Injection Molding is an advanced process that can reduce the amount of labor needed in injection molding. Mainly because it only requires one machine cycle. This means that in comparison with other steps of manufacturing where you have multiple cycles for each operation, your labor costs will come down by 50%.

In addition, two-shot injection molding also has the ability to provide more items per run. This would otherwise not be possible if they used traditional techniques like die or platen press machines!

Quality Products Are Produced Via Two-Shot Injection Molding

The two-shot injection molding process produces high-quality products, which appeal to the consumer. This improves color accuracy and extends the life of colors compared with painting them on.

Eliminating this step while also increasing sales because consumers like how their product looks better without having too much paint running off or being easily wipeable away. In some cases where you can still see remnants after wiping up the excess liquid from spilled food items etcetera!

With the two-shot injection molding process, your product can be both stronger and lighter than if it is created by conventional methods. With a stronger bond without any need for adhesives or glue; ergonomically designed fittings inherently reduce misalignment in production lines. Thus, this offers you a more efficient design while reducing downtime caused by work stoppages!

Injection Molding with Two Shots Is Versatile

Two Shot injection molding process is Versatile and ideal for any industry. We prefer this versatile method of creating molds because you can apply it to a variety of industries. For instance, you can use them for aerospace.

Also, it has an extensive need due to the high cost associated with manufacturing certain parts-to-consumer products like baby bottles or military equipment. The durability offered by these tools makes them invaluable no matter what your application may entail. They’ll last through anything that comes their way!

Conclusion

The advantages of a 2-shot mold supplier are numerous. From the ability to produce more parts in less time, lower capital expenditure, and higher quality product with better surface finish it’s clear that this is an excellent choice for any company.

It is the perfect solution for companies who are looking to increase their business! If you have an interest in learning 2-shot molds, what a 2 shot mold can do for your operation, please feel free to contact Tiptopmolds.com today!

 

What to Know About Overmolding?

Overmolding is a manufacturing process where resin and surfactant are added in an article of manufacture. This creates the feeling that it is dipping in chocolate or putty for example, which leads many people to refer to these objects as “resin castable.” Overmolding is described as a process where one part of the product, usually an insert or shell-type item such as a case for your phone and screen coverings is creating to using two different materials. The first material (substrate) becomes partially covered with additional layers during production; these subsequent molding surfaces are called “overlays.”

What Exactly Is the Substrate?

The substrate is the primary piece in what will ultimately turn into a solitary nonstop part made out of synthetically reinforced and frequently precisely interlocked materials.

It could be anything, from metal machined parts to plastic molded products or even threaded inserts for screws; all made by brazing together various pieces that are designed specifically for this purpose!

What is the Overmolding Material?

The Overmolding Material is a plastic that is mixed with additives like colorants, foaming agents, and other fillers. It begins as pellets in pellet structure before they are warm-up to their dissolving point. So it tends to infuse into the form tooling when you press “submit.” now and again.

However, there are limits on what materials function admirably for this interaction on the grounds that not all plastics will bond together pleasantly – particularly on the off chance that one piece of your end result requires metal parts all things being equal!

What Is the Purpose of Overmolding?

The overmolding process is useful for a number of reasons, but the most common material is toothbrushes. They are often applied in order to create tool handgrips and handle cordless drills or screwdrivers with ease!

In addition, it’s also possible that you’ll come across personal care products like shampoo bottles and razors if your project involves those kinds of items as well.

Here we discussed a few examples of typical overmolding applications:

Plastic Over Plastic

For those who want their product to stand out, over-molding is a great way of doing it. Plastic Over Plastic – first you have the rigid plastic that’s being molds into an object or design on top another layer which is texturing and/or colouring differently than its sibling.

Rubber Over Plastic

To give something a soft grip, you can use rubber over plastic. A rigid plastic is first molded and then the TPE (or other type of accessory) will be applied to or around it in order for its surfaces to come into touch with each other so that user feels less resistance when gripping onto them firmly.

Plastic Over Metal

Many industries rely on overmolding to create a part with the desired characteristics. Plastic Over Metal is one example of this process, where first metal parts are machine and then inserting into an injection molding tool so plastic is adding around it for shape or coloration purposes- often capturing these components in between two pieces that are original designs without them being there at all!

Rubber Over Metal

Overmolding can be used in a variety of ways, often to give some extra grip or cushion. One common application is rubber over metal. First, the surface needs machining before casting it with either natural rubber-like silicone-based ones. Which are more durable than their synthetic counterparts. However, they are still soft enough not to cause discomfort when pressing against them for long periods. Then you put these into injection molding tools so that your final product gets forming around its base material (in this case both hard and plastic).

You could use TPE instead. Thermoplastic polyurethane elastomers provide better traction on smooth surfaces without being too bulky at all times. 

A Few Things to Note:

A product can have more than two materials. Some products use three different surfaces on one part in order to achieve color breaks and grip, like scissors!

How is the Overmolding Process Typically Performed?

Injection Molding is a process that overcomes many of today’s manufacturing hurdles. Overmolding has been around for years, but it continues to grow in popularity. There are so many benefits when compared with other methods like casting or pushing parts through a die using machine tools. This includes improved precision and surface quality, as well as reduced energy consumption due to less tool, wear common during machining operations.

Injection molding goes one step further by allowing manufacturers greater control. They can change certain physical attributes such as Power grip Strength (the strength required before breaking), parting lines pattern density location, etc.

A good idea is to make sure your substrate and overmolding materials interlock. Bonding these two together will not only be done chemically but also physically. With the use of mechanical components that connect both pieces in some way or another.

Overmolding Standards for Prototypes

Overmolding can be a quick and easy way to add details to an already existing model. For example, at tiptop molds, we use our overmolding service for creating prototypes with soft rubbery materials that will quickly cure in just 30-60 seconds!

We are also able to control the color or hardness depending on what part needs extra attention. While using injection polyurethane casting resins results in parts being less costly than other manufacturing methods. Such as plastic molding steps often associated with mass production plastics goods.

Why Would you Want to Overmolding?

There are a lot of reasons to over mold. Among the most common, you can do it for aesthetic impacts or in order provide soft grips around certain areas on separate materials and add more flexibility with rigid parts by eliminating manual work altogether-all without having multiple machines have a need at your company!

Final Words

The overmolding process is a great way to produce complex parts with minimal tooling, and it is useful for all sorts of 3D printing needs. Get in touch with us if you’re interested in learning more about how we can help your company develop new prototypes or market existing products using this innovative process. We love helping companies design their next steps!