For more function integration

2K injection molding

With 2C injection molding or multi-component injection molding, assemblies or components that previously existed individually can be integrated into a single part produced in a single manufacturing step. This enables functional integration in a smaller installation space and at lower cost. However, the process is anything but trivial, because the following criteria are important when joining two different melts, which we determine for you in practice. With our 2K injection molding machines and the matching 2K molds, we can answer any technical question and find the right combinations for you according to the following compatibility criteria.

Property compatibility
If both components meet head-on, an interface similar to a weld line is created. Using our 2C tensile bar, we determine the tensile force during the subsequent test and assess the type of fracture (cohesive fracture, adhesive fracture, fracture with low force with insufficient adhesion).
Processing compatibility
If two melts are processed together, the flow behavior of the second, often softer component often suffers. Using our production-related molded part, the 2K cup, the conversion of one component to the other is realized in the mold by means of a rotary table. To monitor the mold filling behavior, the mold is additionally equipped with cavity pressure sensors.
Liability compatibility
Of decisive importance for the design of a function in 2C technology is the adhesion between the two components. In order to determine the characteristic value of the interfacial adhesion, the 2C roll-peel test specimen is sprayed with both components in the same flow direction so that a flow seam-like, overlapping interface is formed. The comparatively large-area interface is subjected to the roll peel test.

Our services for 2K injection molding in detail

Development

Material research and selection using extended material compatibility table
Material development for your applications
Evaluation of the filling and flow behavior of your materials with our 2K cup(molded part catalog)
Mold design with support by injection molding simulation

Manufacturing

Sampling of your 2K tools
Manufacturing of your 2K components
Manufacturing of 2K tensile bars for your tests
Manufacturing of 2K rolling peel test specimens for adhesion tests

Testing

Testing of adhesion and compatibility with the 2C test specimens(molded parts catalog)
Testing even with small amounts of material using special 2K micro parts and test specimens(molded parts catalog)
Damping characterization by means of dynamic mechanical thermal analysis (DMA)

Increase recycling use with sandwich injection molding

Sandwich injection molding, as a special process of 2C injection molding, enables a second component to be injected into the interior of the first component. This processing variant is particularly interesting because it enables recycled material to be injected into the interior of the molded part and, by encapsulating it with a separate skin material ( e.g. a primary material), conceals negative, optical or olfactory effects. The figures show schematically the principle of the process and a sandwich component as an application example. It is tool-free, requires no reworking and is therefore suitable for economical series production.

Oursandwich injection moldingservices in detail

Increase of your recycled content by processing as core layer material
Consulting in the processing of recycled material of various types
Production of your sandwich structures by means of 2K sandwich intermediate plate from A & E Produktionstechnik GmbH
Use of the 2K sandwich intermediate plate as a variable tool for your 2K molds on our 2K injection molding machines
Creation of new, optical effects with the 2K sandwich intermediate plate (marble or recycling optics)
Rheological testing for compatibility of your skin and core materials using our online injection molding rheometer
Save additional weight, material and costs by using blowing agent in the core layer
Design of damping-optimized multilayer systems with viscoelastic intermediate layer
Optimization of skin layer/core layer distribution
Simulative design of the damping properties of your thermoplastic components

Our machine equipment at a glance

2 components injection molding machine

ENGEL Victory 330H 80V / 80 Combi

ENGEL AUSTRIA GmbH

2 components injection molding machine

Battenfeld HM-MK 180/750H/350V

WITTMANN BATTENFELD Germany GmbH

Additional equipment gas flushing unit

CELLMOULD®

WITTMANN BATTENFELD Germany GmbH

Additional equipment mold plate

2K sandwich intermediate plate

A & E Produktionstechnik GmbH

Matching further training

Collage einer Formteilauslegung des Forschungsprojektes GipRis mit Konstruktionsbildern im Hintergrund.

Seminar

21.02. - 22.02.2023

Plastics selection in product development

Plastics are highly interesting materials with further increased potential for product development. A multitude of requirements to which the product is subjected in the application must be reconciled with the most efficient processability possible and a limited cost budget for the material. This seminar explains some basic tools for solving this complex problem. The content of the seminar is to underline the practical approach from the material selection to the real use of the product. Using a housing made of semi-crystalline material with/without filler and a lens made of amorphous material, the seminar content will be taught in a practical way. For further information on the agenda, how to get there, parking facilities and an insight into the script, please see our download box at the top right.

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Seminar

27.02. - 03.03.2023

Injection molding compact in theory and practice

If you are familiar with the basics of the injection molding process, this extension course will give you additional knowledge about injection molding of thermoplastics. We will explain the phases of the injection molding process to you in detail, look at the input variables and their influence on the molded part quality. In an extended practical part, the theoretical contents will be illustrated for you in a practice-relevant way on an injection molding machine. You will find further information on the agenda, how to get there, parking facilities and an insight into the script in our download box at the top right.

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Bunte Kunststoffplatten, die in Kreisform hingelegt sind.

Seminar

01.03.2023

Plastics science for career changers

You do not have a plastics-oriented education? We will provide you with knowledge about plastics, their characteristic values and common additives. Furthermore, you will receive an overview of plastics processing. Demonstrations on important test methods will deepen your knowledge. For more information on the agenda, how to get there, parking facilities and an insight into the script, please see our download box at the top right.

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Schwarze Prüfstäbe mit schwarzen Granulat für die Kunststoffprüfung.

Seminar

02.03.2023

Incoming goods inspection

What are the requirements for incoming goods inspection for thermoplastics? We will give you an overview of the most important test methods. This will enable you to actively apply this knowledge and carry out evaluations in operational practice. For more information on the agenda, how to get there, parking facilities and a look at the script, please see our download box at the top right.

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Anschnitt eines von außen blauen Sandwichformteils mit schwarzer Füllung.

Seminar

06.03.2023

Multi-component injection molding

Various special injection molding processes can be used to produce more complex components that not only offer cost advantages but also higher-quality features compared with individual components, e.g. through increased functional integration. For example, multi-component injection molding can produce composites from several components of the same or different types. A key quality feature in the injection molding of two or more components is the adhesion between the different materials. For this reason, material selection and molding design are particularly important. In this seminar, we will teach you the basics of multicomponent injection molding technology and demonstrate technical approaches to solutions. For more information on the agenda, how to get there, parking facilities and an insight into the script, please see our download box at the top right.

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Nahaufnahme eines grünen Fehlerteils aus dem Fehlerkatalog

Seminar

07.03. - 08.03.2023

Injection molding defects: avoid + eliminate

Unfavorable settings and fluctuations in process parameters during injection molding result in constellations that can lead to molded part defects and cause high economic losses. We provide you with comprehensive knowledge in the recognition and systematic elimination of defects in injection molded parts. In the practical part, we will deepen the process-engineering correlations with you. You will find further information on the agenda, how to get there, parking facilities and an insight into the script in our download box at the top right.

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Werkzeugauslegung einer Spritzgießmaschine im KUZ

Seminar

14.03. - 15.03.2023

Mold sampling: systematic and efficient

Injection molding is highly efficient in the production of large quantities. To reduce time and costs, we will explain the systematic procedure for mold sampling and give you practical instructions for action, which we will illustrate in the practical part in our technical center. For more information about the agenda, how to get there, parking facilities and an insight into the script, please see our download box at the top right.

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Seminar

15.03. - 16.03.2023

Polymer analytics

Polymer analysis is still very important in the laboratory world. In this seminar, you will be introduced to two essential methods in detail: solution viscosity and contact angle measurement. Both cover relevant material properties and you will have the opportunity to have these techniques explained in theory and practice. The seminar is held in cooperation with LAUDA Scientific. You will be introduced to capillary viscometry for the determination of molecular parameters by means of the determination of the viscosity number, the IV-value and the K-value. In addition, you will be familiarized with the technique of contact angle measurement, and selected analytical methods will be presented. The emphasis is on very practical demonstrations of both techniques. Measurement series for automated dilution viscosity as well as gravimetric sample preparation will be examined and typical sources of error in everyday laboratory work will be pointed out. The Kunststoff-Zentrum Leipzig will provide an insight into the analytical methods used there.

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Seminar

16.03. - 17.03.2023

ONLINE - Injection molding beginner course

You don't have the opportunity to attend our beginners' course on site but would still like to learn the basics about thermoplastic injection molding? Then book our online seminar and get an overview of the aspects plastics, machine, process and mold. You can find more information about the agenda in our download box at the top right.

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