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Challenges in multi- component injection molding Martin Varch Philips Austria GmbH December 12, 2013
December 12, 2013 1
Challenges in multi-component injection molding
Martin Varch Philips Austria GmbH
December 12, 2013
December 12, 2013 2
Challenges in multi-component injection molding
Content
• multicomponent injection molding
• Factors of influence
• Examples – Arielle Housing – Waterfall
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Injection molding Schematic figure
ejector
cavity
sprue
nozzle
heating elements barrel
screw
hopper
drive
mold
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Injection molding
Screw rotates and
fills the barrel
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Injection molding
Screw rotates and
fills the barrel
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Injection molding
Screw rotates and
fills the barrel
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Barrel is filled and ready for injection
Injection molding
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V
Injection molding
injection
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V
Injection molding
injection
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V
Injection molding
injection
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Cavity is full switch over to holding pressure
P
Injection molding
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P
Injection molding
holding pressure
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Injection molding
Cooling and shrinking
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Cooling and shrinking
Injection molding
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Injection molding
Cooling and dosing
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Injection molding
Cooling and dosing
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Injection molding
Mold opens and throws the part out of the cavity
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Injection molding
Mold opens and throws the part out of the cavity
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Injection molding
Mold opens and throws the part out of the cavity
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Injection molding
ejecting
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Injection molding
ejecting
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Injection molding
ejecting
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Injection molding
ejecting
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Injection molding
Mold closes and process start again
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Injection molding
Mold closes and process start again
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Injection molding
Mold closes and process start again
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Definition
• A process of making a part from more than one material in the same
production process.
• Different multi-component injection processes: – two-component – co-injection – over-molded – multi-material
Multi component injection molding
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process
Multi component injection molding
Mold is open, plasticization begins Injection of component A, holding pressure and cooling time
Opening of next cavity, injection component B
Ejection finished 2 K part after holding pressure and cooling
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Factors of influence
Multi component injection molding
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Arielle Housing
Examples
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Arielle Housing Requirements
– Part for water tight epilator – High gloss surface
– Switching function included – No injection point(s) visible
– No Parting Lines visible
– Molded 3D deep-view effects
– Hidden LED
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Arielle Housing Challenges : Technology choice
1. 2 x 2 k + Pins 2. 4 k + Pins 3. …..
Step 1: 3 k Panel Step 2: 1 k Housing + Pins
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Arielle Panel Challenges: Out-washing effects of design-layer
1. DOE with 32 materials to get best
performance
1st Layer PC 2nd Layer MABS
Build a kind of jump for 2nd component
1st component
2nd component
2. Injection situation
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Arielle Housing Challenges: Seal the 3D contour of Panel
die (ejector side side)
Pin slider slider
die (nozzle side)
Housing Panel core
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Waterfall Main Cover Overmold
Examples
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Waterfall Main Cover Overmold Requirements
• Water tight
• Deep view effect
• Switching function included
• No parting lines visible
• Hidden LED
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Waterfall Main Cover Overmold challenges
3rd Component without additional injection unit
Main Cover
switch
Main Cover
Additional 2-component insert part
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Waterfall Main Cover Overmold Challenges: out washing effects
no other possibilities to inject (thick wall <7mm high gloss)
Injection point
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Thank you
