Injection moulding

2K Injection Moulding

Two materials, one production process. This allows hard/soft combinations to be produced fully automatically in a single machine.

Two materials in one product: this is how we create smart combinations

Bij 2K spuitgieten worden twee verschillende kunststoffen in één productieproces permanent aan elkaar gehecht. Dit kunnen hard/zacht combinaties zijn, maar ook soortgelijke materialen in verschillende kleuren.

2K injection moulding is an advanced process that requires specialised 2K injection moulding machines and employs innovative moulding techniques to ensure the materials are combined correctly.

Combinations of materials

Would you like to combine the properties of two materials in a single product? If so, these materials can be bonded together using two-component injection moulding. However, many technical materials do not adhere to other materials.

Met onze zeer omvangrijke ervaring vanuit het verwerken van zachte kunststoffen, mogen wij ons een ware specialist in TPE noemen. Hard/zacht combinaties zijn de uitdagingen waar onze expertise het meest zichtbaar wordt. 

If a combination of two materials is required that simply cannot be joined thermally, De Beer Plastics also knows of alternative ways to develop a perfect two-component product.

Moulds for multi-component injection moulding

Much of the challenge of two-component injection moulding lies in the mould. De Beer Plastics has been manufacturing its own two-component moulds for over 20 years and has developed numerous solutions in this field.

There are various techniques for making the transition from the first step (material 1) to the second step (material 2).

  • Rotary table – where the mould opens and one mould half rotates 180 degrees

  • Indexable core – where the mould opens, a core moves forward and rotates 180 degrees

  • Robot transfer – whereby the mould opens and a robot removes the plastic part from the first stage and places it back into the second mould cavity

  • Core-back system – whereby a core retracts inside the mould, creating space for a second material

  • Overmoulding – a process in which pre-manufactured components are inserted and then moulded over

De Beer Plastics is proficient in all these techniques and can therefore select the best technique for your product. This depends on the product’s geometry, as well as the combination of materials and the batch size.

2K or 3K

The possibilities of multi-component injection moulding go beyond simply combining two materials. We are also capable of combining three materials. For smaller production runs, we often use a combination of automated two-component injection moulding with an overmoulding step, whereby a component is placed in a separate machine and overmoulded.

However, for larger production runs, it is possible to combine three different materials in a single mould and on a single machine. Ask us about the possibilities of 3K injection moulding.

2K injection moulding is used for a variety of reasons:

Assembly

By joining two components together using injection moulding, an assembly step can be eliminated. This removes a production step and saves money.

Sealing

An additional component can form a seal between other parts. By injecting this component directly, there is no need for a separate seal. Furthermore, the joint between the soft and hard components is completely watertight and airtight. This significantly reduces the risk of leakage.

Haptics/ergonomics

Multi-component injection moulding can be used to give a product a non-slip or rubber-like finish. This makes it possible to add value to the products. Personalised product variants can also be created by varying the colours.

Information/colours

By using a second colour during the injection moulding process, text or symbols can be applied. This information can be applied directly to a product without the need for additional work, such as printing.

Moulding challenges into Reality

STEETS