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

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I help you!

Carsten Holland

Head of Processing Technology Department