Double Injection, sometimes known as 2 material 2 shot molding or 2K molding, is an innovative manufacturing process used to produce complicated molded parts from two different materials. Through a highly specialized and automated process we carefully control the injection of multiple materials, including two different kinds of resin, into a single, multi-chambered mold.
2 shot molding in performed on one machine that is programmed to perform two injections in one cycle. In the first cycle, a nozzle injects plastic into a mold. The mold is then automatically rotated and a different type of plastic is injected into the mold from a second nozzle.
2 shot Molding optimizes co-polymerization of hard and soft materials to create powerful molecular bond. The result is a single part with production and feature advantages. It can be used for a variety of product designs across all industries. It also allows for molding using clear plastics, colored graphics and stylish finishes which improves your product functionality and marketplace value.
There are two phases of the 2 shot molding process. The first is similar to traditional injection molding: A shot of resin is injected into a mold and cooled to form a solid part. In the second phase, the just-molded part is transferred to a second mold via a rotating platen or a robotic arm, and receives the second shot of resin – in, through or around certain parts of the first molded part, depending on the design. The two plastic resins then form a molecular bond and the multi-resin molded part is cooled and ejected.
The process isn’t difficult to understand, but it’s highly difficult to master. It requires high levels of technical expertise and attention to detail, and even the smallest mistakes can cost big money, especially in high-volume production scenarios.
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