In today’s market, consumer products are increasingly characterized by their dynamic designs, aesthetic appeal, and sophisticated functionality, necessitating a quick response to market trends.
Designers often opt for various materials depending on the specific application of consumer products to address particular environmental needs, aiming to enhance product durability, visual appeal, and practicality.
However, this requirement for practical design complicates manufacturing processes. Consequently, the bi-material injection technology utilized in vertical two-component injection molding machines has emerged as a viable solution.
While standard bi-material products can be produced using a single-color injection molding machine, the associated post-processing steps tend to be complex. This complexity can adversely affect product quality and result in higher production costs, making it less economical.
In addition to modifications to the injection molding machine itself, mold design plays a crucial role in this technology. By strategically positioning the molds, it becomes possible to achieve synchronous injection of different materials.
Mold design can be categorized into two main types: one involves two mold cavities that use a rotational mechanism to transfer the semi-formed component to a different cavity, allowing simultaneous execution of the first and second processes. The other type is a single mold cavity where the semi-finished product rotates 180 degrees, resulting in a simpler design but potentially lower production efficiency.
Given that the mold or semi-finished product must rotate, precise mold design and exact specifications for the injection molding machine are necessary. Furthermore, due to the inherent variability in double (multi) material injection molding, it is essential for mold designs to align with product specifications. Manufacturers often face inconsistencies in the specifications of vertical two-component injection molding machines, leading to additional considerations in mold design.
Typically, dual-material products are composed of hard plastics such as ABS or PC combined with soft plastics like TPE. This combination is ideal for producing two-color tableware, tool handles, straps, chips, and buttons.
This scenario prompts manufacturers to focus on material integration, product complexity, and the required adjustments in injection molding technology. For instance, cost and application factors may lead to inadequate adhesion between the materials used, necessitating careful adjustments during the bi-material injection process in vertical two-component injection molding machines.
