For more function integration
2K injection molding
With two component (2K) 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 2K tensile bar, we determine the mechanical properties in our accredited testing lab of the tesile bar 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 2K technology is the adhesion between the two components. In order to determine the characteristic value of the interfacial adhesion, the 2K 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.
- Material research and selection using extended material compatibility tables
- Material development for your applications
- Evaluation of the filling and flow behavior of your materials with our 2K cup
- Mold design with support by injection molding simulation
- Sampling of your 2K tools
- Manufacturing of your 2K parts
- Manufacturing of 2K tensile bars
- Manufacturing of 2K rolling peel test specimens for adhesion tests
Sandwich injection molding, as a special process of 2K 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.
Our sandwich injection molding services 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
17.10. - 18.10.2023
Ultrasound - plastic welding
Welding by means of ultrasound is a fast and reliable variant for joining plastic components. In this course, we provide you with the necessary knowledge from the basics to practical application. To deepen your knowledge, we will demonstrate the processes in the practical part. 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.
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.
24.10. - 25.10.2023
Basics of thermoplastic foam injection molding
Demands for more sustainable solutions and increased functional integration can be met by foaming thermoplastics. The resulting lightweight construction due to the lower density is also a topic that is more topical than ever. This seminar will provide an overview of various processes, the associated machine and mold technology and, above all, the further processing of foamed plastics. 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.
25.10. - 26.10.2023
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.
Injection molding defects - Recognition and assessment
Injection molding is comparatively complex due to the many processing parameters involved. Unfavorable settings and fluctuations in the process parameters result in constellations that can lead to quality defects and damage to injection molded parts. In this seminar, we will give you an overview of defect patterns and their causes and discuss the background and possible elimination strategies with you. 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.
Use recycling cleverly! - Seminar
The recycling of plastics is an essential part of closing material cycles in order to save fossil resources and waste in significant dimensions. In times of raw material shortages and rising prices, it can thus become an integral part of a sustainable and economically viable material supply. When it comes to practical implementation in injection molding operations, it is important to know the special requirements of the material and the processing technology. The seminar will provide the necessary know-how to find climate-friendly, economically advantageous and process-reliable solutions adapted to the respective application. For more information on the agenda, how to get there and where to park, please see our download box in the top right-hand corner.
01.11. - 02.11.2023
Injection molding beginner course
Injection molding is one of the most important processes in plastics processing. In this course, you will learn the basics about injection molding of thermoplastics and we will present an overview of the aspects plastics - machine - process - mold. In addition, the theoretical content will be illustrated for you on an injection molding machine with practical relevance. You can find more information about the agenda, travel, parking and an insight into the script in our download box at the top right.
01.11. - 02.11.2023
Use recycling cleverly! - Seminar + Workshop
The recycling of plastics is an essential part of closing material cycles in order to save fossil resources and waste in significant dimensions. In times of raw material shortages and rising prices, it can thus become an integral part of a sustainable and economically viable material supply. When it comes to practical implementation in injection molding operations, it is important to know the special requirements of the material and the processing technology. The seminar provides the necessary know-how to find climate-friendly, economically advantageous and process-reliable solutions adapted to the respective application. In the compounding workshop, you will also gain practical expertise for the application case. For more information on the agenda, how to get there and where to park, please see our download box in the top right-hand corner.
Plastic detection made easy
You want to identify plastics without analytical equipment? With the help of a detection scheme, we show you how to identify plastics with simple means. For further investigations, we will introduce you to selected methods of instrumental analysis for plastics detection. For more information on the agenda, how to get there, parking facilities and an insight into the script, please see our download box on the top right.
Plastic innovatively shaped
Injection molding, along with other major plastics processing methods, is one of the most widely used primary molding processes.