Injection molding is a technique that has been used for many years to create all kinds of unique products. There are many types of it that are used today, and among those, the most common would be two-shot injection mold. The process has been around for many years and continues to be upgraded as years go by, with many manufacturers around the globe making use of it.
This is a Two-Shot molding design guide that will look into the process in detail, on how it is used, why you should go for it over other forms of molding, and the things you have to pay attention to when you decide to go with it. Stick around if two-shot injection molding is something you have been considering assimilating into your manufacturing process.
Going by the name, the two-shot injection molding process makes use of two injections rather than one as is the case with the regular type of injection molding. The process is not any different either, it begins by the clamping of a special mold designed to accommodate the double injections in such a way that it doesn’t require the ejection of one finished part while the other is still cooling down.
Once the mold is closed tightly, the runner for the first cavity is aligned for the first injection. At the same time, the hot runner for the adjacent cavity is closed off. The first cavity is filled to the brim in the normal injection manner. This is followed by the 180-degree rotation of that first cavity to align with the second cavity; the first cavity is then sealed off as the second one is filled up with molten material. All through the entire process, at no point are the materials ejected or shifted while they are sealed in the mold; this ensures that the end product looks exactly as the mold and that both come out identical.
There are many benefits associated with two-shot injection molding, and they are the reason why the process is being adopted by many manufacturers across the globe. The following are the notable advantages of using it in the assembly line.
Precision: With a two-shot injection, you are assured of uniformity, and that’s the level of precision that most manufacturing processes are unable to replicate. When using the same molds for each batch, your consumers will be able to appreciate the quality of the products as they will see the consistency displayed, and this boosts the confidence in your brand.
No Wastage: With two-shot injection molding, as is the case with other types of molding, there’s very little wastage of raw materials since the injections are controlled, and nothing is allowed to spill over. In the event that some materials are left over, they can always be recycled back into the production liner as many times as possible without losing their quality.
Cost-Effective: The initial setup can be too high for many people, but the returns once things hit the road running are immense. Two-shot injection molding is an automated process that relieves you of the burden of paying salaries and compensation while bringing speed and accuracy to the table. Production gets doubled while your expenses go down.
Aesthetics: Products that are made using two-shot injection molding look stunning. They come out with very few surface blemishes. The process also allows for custom art to be added through the mold. The entire process is also well controlled from the heating to the colling patriot, and this balance is what makes the end-product look very refined and classic.
Durability: Two-shot injection products are built to last no matter the type of materials used. Each part of the entire process imparts good qualities to the product, and by the end of it, they come out with great structural integrity. This is the reason why the process is used to make parts that are used in the automotive and aerospace industries.
Reduced Production Time: With automated systems and fewer human workers, the speed of production has doubled up, and this increases profits. The general time it takes for a single batch to be made is about two minutes. The robots involved ensuring that there are no delays in between, and this boosts the production to a level where demand is able to be met much faster.
High Design Range: You are only limited by your imagination when it comes to two-shot injection molding. It is none of the most versatile processes as far as designs go. You can create just about anything you can think of in large quantities. All you need to do is come up with a unique design concept, create a mold for it, and you will be making unique products that cannot be replicated anywhere else in no time.
Reduces Need for Extra Parts: What used to require the joining of many independent parts to make one whole component can now be made in one go without a need for extra processes. This not only cuts down the production time but makes the end products stronger as they will not have any lines of weakness that can lead to breakages when extreme pressure is applied on them.
Integrated Functionality: Two-shot molding is an all-encompassing process. You can choose to interpret everything in the process and have the product come out the other end, complete with everything you need. This includes engraving logos and texts, use of color layers and gradients, and anything you may need to be added. All these processes used to require a separate production unit.
There are countless ways through which two-shot injection molding can be utilized in the modern world. The process is convenient and versatile, and almost every sector of the manufacturing world uses it in one way or another. The following are some of the notable applications of the molding process.
You may have seen simple plastic toys made for babies in shops and how complete they are with no sign of an opening or seam. These types of toys can only be made using two-shot injection molding, and they are not only safe but are very durable to the point they can withstand any rough handling, something that’s very common among children.
Plastic-based items like toothbrushes, soap holders, and others are some of the toiletries that depend on a two-shot injection molding process. The process is the only one more suited for making the toothbrushes flexible and strong enough to be handled with strength without breaking apart.
There’s no household that can do without plastic containers. From the kitchen to the bathroom, every part of the house requires some forms of containers for cleaning and storage. The same applies to business premises and other establishments. These containers are products of two-shot injection molding, and they have to be solid and strong to handle the many tasks they are put through around the house.
From plastic syringes to bone saws to rubber grips, and anything used in hospitals is made using the two-shot injection method. The process is preferred for its accuracy and precision when it comes to sizes and textures. Medical tools have to be very accurate since they are used on people, and if they are off even by a small margin, they could cause untold problems for patients.
Electronic products depend on insulation for them to perform well and to reduce the dangers of electrocution. But that could take a lot of space if they are not handled well, and that’s where the two-shot injection method comes into play. It can be used to make even the tiniest of plastic cases for all kinds of electronic components.
Gardening tools are other essential products that are found in every home that has a backyard, from shovels to buckets, vases, and other products that are used for various tasks outdoors. All these are made using two-shot injection molding, and they can be made in any size, color, and using any type of material.
Like any other manufacturing process, two-shot injection molding requires proper planning and investment for it to work without any issue. For this reason, there are some things that you have to keep in mind when going for this method, and they include the following.
Your Budget: You need enough funds to set up a complete two-shot injection unit, and this involves getting automated industrial robots, technicians who will run them, enough space to set them up, and maintenance costs for emergencies. This requires significant capital.
Raw Materials: You need to know in advance the type of raw materials you will be using and the type of product you intend to make. If you choose to go with plastic, then find injection molding machines that are designed for that as they are different from those built for metals. Deciding this early on will save you a lot of headaches.
Versatility: How easy will it be to switch to new designs on the move? The one thing with manufacturing is that demand rises and dips without warning, and you have to be ready to ride this wave by having the ability to adapt to new products on the fly. Having an injection molding system that can be switched up at a moment’s notice will save you a lot of money.
Like many other molding processes, two-shot injection molding is quickly gaining traction with manufacturers around the world, thanks to the efficiency it brings to the table. All factors indicate that injection molding is the technology of the future; itwith and anyone who is yet to embrace it is losing ground. For more information on two-shot injection molding and how it works in detail, visit our website and gain access to unlimited information that will help you know the direction to take.