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
29.11. - 30.11.2023
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.
29.11. - 30.11.2023
Rheology and thermal analysis
The description of the material properties of plastics is essential for the design of processing procedures and for quality assurance. Rheometric investigations can be used to characterize the flow and deformation behavior of thermoplastic polymers and to better understand their structure-viscosity behavior during processing. The test methods of thermal analysis open up the possibility of identifying relationships between processing conditions, microstructure and material properties of plastics. In this way, polymers can be identified and processing-related material damage can be detected. In this seminar, the theoretical fundamentals of rheology and thermal analysis are combined with practical demonstrations of the equipment in the laboratory and pilot plant. Concrete application examples from the practice of the accredited testing laboratory at the KUZ will be used to show what information can be obtained from the recorded measurement curves. 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.
Professional color measurement in the industry
Learn more about the basics and limitations of color detection as well as the goals and benefits of color measurement. We will explain suitable color measurement techniques and introduce you to colorimetric evaluation on products. 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.
Plastic innovatively shaped
Injection molding, along with other major plastics processing methods, is one of the most widely used primary molding processes.