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Processing Technology

Examples of
multi-component mould designs

Know-how Edition
Processing Technology

Examples of multi-component mould designs

1. Denition of multi-component injection moulding

Process technology

Numerous processes have already been developed and successfully

implemented for producing multi-coloured plastic parts. Such processes include printing, hot stamping, vacuum deposition, or coating,
laser inscription, the in-mould laminating of printed lms as part of
the IMD process, assembly of individually moulded parts of various
colours, and last but not least multi-component injection moulding.
All these processes are tried and tested. When deciding on the ideal
production method it is important to carry out a comparison of the
various options and the different procedures. This is particularly true
when it comes to multi-component injection moulding.
Multi-component injection moulding may offer a huge range of possibilities, but these can only be used to the full if there is due regard for
the manufacturing process when the moulded part is being designed.
What really matters in this respect, in addition to the machine equipment, is the mould, the moulds construction and the manner in
which it functions, since not all parts can be produced according
to the same mould concept. The following documentation therefore
provides an overview of the various mould concepts implemented in
the area of multi-component injection moulding.

Multi-component injection moulding

Multi-component injection moulding is a blanket term covering all
those processes that involve treating and processing more than one
plastic component. This makes it possible to introduce the melt into
the cavity via one or more sprue systems inside the mould.
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Two of the processes that can be performed with a sprue system are
the techniques of interval injection moulding and sandwich injection
moulding, both of which entail the use of a special nozzle to combine
the melt streams and deposit them in the conventional mould.
The following document deals exclusively with processes that involve
several sprue systems and with the special mould technology associated with these. A clear distinction is made in the document between
multi-colour and multi-material injection moulding. Multi-colour injection moulding refers to cases where the same material is processed in
a variety of colours and multi-material injection moulding to situations
where different types of material are used.
Multi-colour injection moulding

Multi-colour injection moulding involves the production of parts that

are made from different coloured plastics. The individual components are not merged, but are kept strictly separate. This means that
visual effects can be created by combining areas of different colours
or even transparent and optically conductive areas. As a result, the
moulded parts are resistant to external inuences such as chemical,
thermal and mechanical loads.

Illustration: Examples of multi-colour injection moulding

Multi-material injection moulding

Multi-component injection moulding does not just allow different

colours of plastic to be combined, but also different types of plastic.
That is why reference is also made to multi-material injection moulding or two component injection moulding.

Hard-soft combinations

A large proportion of these two component applications are made

up of what are known as hard-soft combinations. In the majority of
cases, hard-soft combinations consist of a thermoplastic and a thermoplastic elastomer. Consequently, components can be produced,
which, in addition to having a hard and abrasion-resistant basic
body, also feature soft areas that are able to act as seals and shock
absorbers, or can make the part more comfortable to hold (better
handling).

Adhesion

When combining different materials, attention should be paid to the

adhesion properties of the raw materials, as well as to the differences in their shrinkage and thermal expansion properties and their
processing temperatures. The adhesive strength which is attained
in the interfacial areas may be produced by chemical bonding or
mechanical anchoring (e.g. undercut shapes).

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Illustration: Examples of hard-soft combinations

Elastomer/LSR and thermoplastic combinations

In addition to combining thermoplastics with TPEs, it is also possible
to create hard-soft combinations from thermoplastics and elastomers
such as NBR or liquid silicone rubber (LSR). However, heat separation
inside the mould becomes a problem here, since higher temperatures
are required for vulcanisation of the elastomers. Even the cold runner
systems that are often used for processing LSR, and which prevent
premature cross-linking of the material inside the sprue, must be thermally insulated from any hot runner systems that might be used for
the thermoplastic components. Of course, with this procedure only
those thermoplastics that can withstand the short-term high vulcanising temperatures of the elastomers can be used as the other material
in the composite.

Illustration: Hard - soft compounds made from thermoplastics and liquid

silicone rubber (LSR)

Assembly injection moulding

In addition to bonding materials in such a way as to make them practically inseparable, it is also possible to join together two incompatible materials to make one moulded part. Due to the geometry of the
moulded part and the difference in the shrinkage properties and compatibility of the materials, two halves are created which are attached
to one another in such a way that they can move. This means that
when the moulded part leaves the mould it is already equipped with
an integrated joint, which enables it to move. This dispenses with
the need for a distinct assembly process at a later stage. Examples
of applications include moveable air exit aps for vehicle interiors and
action gures.
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2. Mould concepts for multi-component injection moulding

Along with the machine equipment, the mould, its construction and
the manner in which it functions are of the utmost importance. In
order to take full advantage of what multi-component technology has
to offer, there must be due regard for production when the moulded
parts are being designed. It is therefore necessary for part designers
to work closely together with mould engineers, since not all parts can
be produced using the same mould concept.
Mould concepts

In principle there are two different types of mould concept. The rst
involves transferring the pre-moulded part to another cavity by means
of a rotary movement, by hand or by using a robotics system, so that
it may then be encapsulated by the second component. This entails
switching from one mould cavity to another.
The second concept involves the use of internal movements inside
the mould to free up space for the next set of components, i.e. only
one cavity is used.

Rotary moulds

The rst process step to be performed when using rotary moulds

is the initial production of a pre-moulded part in one of the cavities.
Subsequently, during the next step, the part is manoeuvred into the
required position by transferring it into a second cavity by means of
a rotary movement of 180, so that it can be encapsulated by the
second component.

The advantage of using rotary moulds is that pre-moulded parts can

be produced at the same time that parts are encapsulated by the
second component.
Depending on the geometry of the part, the following different design
systems are available for performing the rotary movement, whereby
either the entire mould half or individual parts of the mould are
rotated:

Rotation of a stripper plate

Rotation of a platen by means of an ejector movement
Rotation of an insert
Rotation of the moveable mould half
Rotation of a central platen

Far more is expected of rotary moulds in terms of precision than of

moulds used to produce plastic parts of just one colour, because they
must be spot on.
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Altering the mould using an internal movement inside the mould

By shifting the cores or sliders inside the mould as part of the composite injection moulding process, hollow spaces can rst of all be
closed off and subsequently reopened (see illustration).

The mould can be congured in the following ways:

Lifting and lowering movements
Sliding movements
The advantage offered by this process is that parts can be produced
without the need for intermediate opening of the mould and without
further transport of the pre-moulded part. However, production is
performed in a strict sequence, whereas with rotary moulds simultaneous operations are possible.
Transfer by hand or robotic system As an alternative to the rotary movement, the pre-moulded part can
also be transferred from the rst cavity to a second one ready for the
nal injection stage, either by using conventional means (i.e. by hand)
or a robotic system.
Transfer is extremely advantageous when working with cross-linking
materials such as liquid silicones (LSR), because the mould can be
divided into two distinct halves, each of which is completely thermally
insulated from the other.
Simultaneous direct injection

Another variation is the direct simultaneous injection of two components into a single cavity, without having to alter the mould. However,
the inevitable consequence of using this process is an uneven dividing line between the two materials with the result that it is only used
for parts whose ultimate visual appearance is not of prime concern.

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3. Examples of multi-component mould designs

3.1. Rotary moulds

With multi-component injection moulding the pre-moulded parts are

generally transferred by means of a rotary movement as described
previously. All of the processes - multiple injections, transport of the
pre-moulded part, ejection of the nished parts and demoulding
of the sprues - are performed automatically as part of the machine
cycle. Consequently, the mould has an extremely important part to
play here, because it comprises the entire process.

3.1.1 The ARBURG indexing unit

As described previously, where multi-colour technology is used, the

pre-moulded part is generally transported by means of a rotary movement. This may be performed on an alternating or on a continuous
basis and may include rotation of the entire mould half or the rotation
of one index platen only. Since the installation of an appropriate rotary
drive mechanism in the mould is both time and cost intensive, indexing units have been developed which are mounted in a xed position
on the moveable machine mounting platen and which may be utilised
universally for different moulds.

Illustration: ARBURG indexing unit designed to be mounted on the moveable

mould platen

Indexing units that are geared towards specic machines are a

worthwhile accessory for multi-colour injection moulding and enable
the costs associated with the mould to be reduced considerably.
Since the cost of a machine-related indexing unit is only marginally higher than that for a drive directly integrated into the mould,
the investment usually starts paying off from as soon as the second
mould. There are generally no technical restrictions on the functionality of the moulds.
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Hydraulic drive

The drive for the indexing unit consists of a hydraulic motor, which is
connected and programmed via the core pull control. Pneumatic and
temperature connections for the mould are guided through the centre
shaft.

Electric indexing unit

Indexing units with a servo-electric drive permit much quicker movements compared to hydraulic indexing units. These movements
can also be carried out independently of the hydraulic axes of the
machine. An additional advantage of the electric drive is that the nal
position can be reached with the utmost accuracy without the need
for any nal mechanical stop dogs. All the movement sequences and
angles of rotation can be programmed directly via the control system
and saved together with the mould record.

Illustration: Indexing unit with servo-electric drive

Construction and functioning of the indexing unit

The following illustrations show an indexing unit for rotating the
entire moveable mould half by 180 or 120. It consists of a rotating
inner platen and a xed backing platen which is screwed onto to the
mounting platen of the machine. Roller bearings are used to hold the
rotating inner platen to its outside diameter, so that it cannot tip forwards. It is driven by an externally located hydraulic motor and the
nal positions are marked by mechanical positive stops.
The cooling water supply for up to four separate temperature control
circuits is connected to the side of the xed platen and is supplied
internally to the mould via the centre spindle. Accordingly, the bores
for the cooling system must be central to ensure that the mould can
be connected. What is more, once the nal positions have been
reached, the moulds ejection system can be connected to or disconnected from the machines hydraulic ejector system so that the
moulds full functionality is ensured. In addition to performing the
ejector movement, it is also possible to perform a lifting or lowering
movement inside the mould by means of a stop dog.

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Construction and functioning of indexing units

3

11

1
4
6

10

5
9
Indexing unit for alternate rotation of the moveable mould half by 180

13

Radial bearings of the rotating platen

Radial bearings of the cooling shaft

Axial bearings of the rotating platen (

roller bearings)

Axial bearings of the rotating platen

(plain bearings)

Stop ring and stop dog

Rotating platen drive

Cooling connections (up to 4 cooling

circuits)

Switch and control cam for nal

position and 2nd speed

Bore for ejector pin

12

10 Bores for lifting and lowering move

ments
11 Mould centring system
12 Stop ring

Indexing unit for rotating in one direction by 120 or 180

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13 Sliding stop dog connected to

hydraulic cylinder

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Rotation of a single insert

For moulds on which only one insert or platen is to be rotated, the

indexing unit can be modied using a special kit so that only one of
the moulds spindles is operated.
In addition, the indexing units cooling shaft is replaced by the drive
bushing (2). An additional platen (3) is mounted onto the ange (4),
so that the rotating platen (1) is free to revolve on the inside and will
only operate the drive bushing (2). A thermostat block (5), which is
connected to the shaft of the mould enables the temperature of the
rotating platen or the rotating insert to be moderated.
So that the rotating insert or rotating platen can be moved backwards
and forwards before rotation, the thermostat block (5) is connected
to the machines hydraulic ejector. This enables the start time and the
stroke movement for the rotating insert to be programmed precisely
via the ejector control system.
If an ejector system is still required for the mould, then this must be
achieved by means of another core pull.

Illustration: Adaptation of an indexing unit

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3.1.2 Rotation of a stripper plate

With this mould concept, a pre-moulded part is produced in the

rst injection direction at the same time that a second component is
moulded onto the pre-moulded part from the previous cycle in the
second injection direction.

The process

Once the holding pressure time and the cooling time have elapsed,
the mould is opened. The pre-moulded part and the nished part
remain attached to the mould core and are removed from the side
that is xed. The tunnel gate connecting with the pre-moulded part
and nished part is detached. The mould moves upwards and the
central spindle that is connected to the rotating platen is pushed
forwards by the machines hydraulic ejector system. By means of
this process the mould cores are removed from the pre-moulded and
the nished parts. An external attachment on the pre-moulded part
ensures that it can come free from the core, but still remains inside
the rotating platen. The nished parts and the sprue for the premoulded and nished parts are now free to drop out of the mould.
The central spindle rotates the rotating platen by 180. The rotation can be performed using a rack-and-pinion device actuated by a
hydraulic cylinder or using an indexing unit with a hydraulic motor. If
the sprues or the nished part have not yet dropped out of the mould
of their own accord, then this will happen as a result of the centrifugal force generated during rotation. Once the rotation has been
performed, only the pre-moulded part will be left inside the mould.
The rotating platen is withdrawn again by the hydraulic ejector. The
second stations core enters the pre-moulded part and lifts it up. Following the close mould operation, it is possible to resume work with
both injection units.
Some typical applications involving the rotation of a stripper plate
are the production of multi-coloured keyboard elements or switches,
whereby abrasion-resistant lettering is incorporated into the component.

Illustration: Examples of applications involving rotation of a stripper plate

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Example 3.1.2: Rotation of a stripper plate

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3.1.3 Rotation of a platen by means of an ejector movement

It is not always possible to work with a rotating platen that also
acts as a stripper plate. So that the advantages of a rotating platen
may be enjoyed (simpler mould construction), this mould concept
also allows the part to be removed from the mould using an ejector system. In this case the injection moulding machine must be
equipped with an additional core pull.
The process

Up until the point where the mould is opened, the procedure is identical to that of the system described above. Once the mould opening
operation has been performed, the nished part is rst of all ejected
by means of an ejector system. The ejector system is operated inside
the mould using additional hydraulic cylinders. The rotating platen
is connected to the machines hydraulic ejector and this prevents
it from lifting up as the part is being ejected. The remainder of the
process is the same as for example 3.1.2, i.e. advancing the hydraulic
ejector, rotating the rotating platen, retracting the hydraulic ejector
and closing the mould.

Illustration: Examples of applications involving rotation of a platen by means

of an ejector movement
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Example 3.1.3: Rotation of a platen by means of an ejector

movement

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3.1.4 Rotation of an insert

Both the mould concept and the process involved here are identical
to those for examples 3.1.2 and 3.1.3. However, in this instance it is
not a platen that is rotated, but a single insert inside the mould. As
the illustrations show, both the insert and the ejector system can be
designed in many different ways.

Illustration: Rotation of an insert

These rst three mould concepts are all used when the mould contours on the moveable and on the xed mould halves have to be
swapped over for the second injection stage.
Nevertheless, by using lifting and lowering movements, in certain
cases it is even possible to change the mould contour for moulds
whose moveable mould half is rotated.
In such an event, the stamp or inserts must be raised and lowered.
These movements inside the moveable mould half can either be
driven hydraulically or pneumatically, or mechanically via the indexing
unit.

Illustration: Examples of applications involving rotation of an insert

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Example 3.1.4: Rotation of an insert

Figure A

Figure B
Design variant: Stripper plate moved by means of a core pull

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3.1.5 Rotation of the moveable mould half

In this design the ejector side consists of two identical mould halves.
As a result, two ejector systems are also required. As a rule, the premoulded part remains on the core of the moveable mould half and
is then rotated by 180 into the second station on the nozzle side,
where it is encapsulated by the second component.

Illustration: Examples of applications involving rotation of the moveable mould

half

Once the mould has been opened, the nished part is ejected by the
ejector system associated with the second injection shot. The ejector system is actuated by an ejector cross, which is connected to the
machines hydraulic ejector.
If the moulds ejector plates are retracted into the nal position or
are actuated a number of times, it is possible to connect the moulds
ejector system to the ejector of the ejector cross (see gure B).
When the rotational operation is performed, the moulds ejector pins
enter a groove in the indexing units rear platen. The moulds ejector pin is connected to the ejection tie bar of the ejector cross in the
ejector station.

Illustration: Ejector coupling

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Example 3.1.5: Rotation of the moveable mould half

Figure A

Figure B
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3.1.6 Rotation of the moveable mould half where two sprue systems are used
If sprue systems are used (during the rst and second injection shot)
in connection with the rotation of the moveable mould half, then the
sprues for the rst and second shot must be ejected along with the
nished parts. This can be performed using two ejector plates, which
are stacked on top of one another.
The ejector pins of the sprue distributor are grouped together on the
front plate that goes all the way through. The ejector pins of the part
are grouped together on the divided rear ejector plates. Both ejector plates can be actuated separately via three ejector pins using the
ejector cross on the machine (gure B).

Illustration: Examples of applications involving rotation of the moveable

mould half

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Example 3.1.6: Rotation of the moveable mould half

Figure A

Figure B

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3.1.7 Rotation of the moveable mould half along with movement of stamps or inserts
In the case of certain applications recesses must be created through
the movement of stamps or inserts. The easiest way to perform these
movements is again through the use of an indexing unit.
Undercut shapes

Undercut shapes for mechanical anchoring of the second component

can be made available by moving stamps or inserts. This becomes
necessary if the two materials to be used in the composite are not
conducive to the forming of a chemical bond.

Illustration: Making undercut shapes available through movement of the

stamp

Moulded parts bearing symbols or characters which are of a different colour

There is a specic type of problem associated with the production
of parts that bear characters or symbols of a different colour. Many
characters and symbols such as A, B and O, for example, contain
one or more islands. These enclosed areas cannot all be injection
moulded individually, but must somehow be combined with the area
outside them.

Illustration: Switch elements bearing symbols of different colours

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The gure displayed below shows the most commonly used method
for lling in the enclosed areas. First, a basic body (pre-moulded
part) is moulded in the colour to be used for the characters (1). The
lettering on this must be embossed. There also have to be recesses
underneath the characters so that the islands can be lled in with the
plastic of the other colour during the nal injection stage (2). Access
to these recesses is achieved by encapsulation with the second component by moving a stamp.

Illustration: Fashioning of the moulded part in cases where there are enclosed
areas

In the case of symbols that are to be illuminated from behind, as is

necessary for switches for the automotive industry for example, the
connection between the islands and the external contour must be
severed when the parts are ejected (see illustration).

Illustration: Fashioning of the moulded part in the case of backlit switches

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The easiest way to move stamps or inserts is to use an indexing unit.

Two platens containing the stamps or inserts are lowered into the rst
station. Depending on the part this can also be performed in reverse.
In order that these lifting and lowering movements may be performed
two bores for each of the mould halves are drilled into the indexing
unit. At the station where the inserts or stamps are raised, two pins
on the rear platen of the indexing unit are inserted into the bores so
that they are level with the platens surface.
There are no such pins in the other station. The platen can be lowered by means of return pins. The pins in the mould can be sunk into
the empty blind holes. During subsequent ejection of the nished
parts (gure B) the platen must be raised along with them. It is only
then that the moveable mould half can be rotated.
The advantage of using rotating platen systems (examples 3.1.23.1.4) is that no additional mechanism is required inside the mould.
The stamps or inserts are simply switched over.

Illustration: Example application involving a hard-soft combination handle

plate

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Example 3.1.7: Movement of stamps or inserts

Figure A

Figure B
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3.1.8 Rotation of a central platen (staged mould)

In the case of certain applications the mould can be constructed as
a staged mould. Pre-injection is performed at one stage, with the
second part being added at the second stage to produce the nished
moulded part. Transfer from the pre-injection station to the nal
injection station is achieved by rotating the intermediate platen.
The advantage of this concept is that it allows the entire surface of
the mould to be exploited. By contrast, in the case of rotary moulds
only half of the moulds surface is available, because it has to be
divided into areas for the pre-injection and nal injection stages.
This type of rotary system also offers advantages with regard to parts
that feature widely differing areas of buoyancy, e.g. casing components with an injection moulded seal all the way round. In a case such
as this, the part can be moulded centrally so that no asymmetrical
buoyancy forces come into play inside the machine. An additional
advantage of this system is the reduction it brings in the injection
moulding machines clamping force.
However, the ip plate system can only be used to a limited extent.
This procedure is not suited to situations where mould contours on
both sides must be switched.
A large number of two-component parts remain on the core on the
ejector side during rotation and are ejected from this side. Where
components of this kind are concerned, the ip plate must be
equipped with two ejector systems, which makes the moulds highly
complex and therefore too expensive.

Illustration: Example of an application involving a staged mould

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Example 3.1.8: Rotation of a central platen (staged mould)

Figure A

Figure B

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3.1.9 Rotary moulds for three-component injection moulding

As a rule, three-component parts are produced using two or threestation moulds.
Two-station mould

Where a two-station mould is used, at station 1 the pre-moulded

part is produced using two injection units, which both inject simultaneously. The pre-moulded part is transferred to station 2 by rotating the moveable mould platen by 180. The nished moulded part
is then produced by encapsulating the pre-moulded part with the
third component. Following opening of the mould, the nished part is
ejected along with the sprues.

Three-station mould

Where a three-station mould is used, at station 1 a pre-moulded

part is produced using the rst injection unit. By rotating the moveable mould platen by 120 the second component can be added at
station 2. An additional rotation of 120 transfers the two-component
part to station 3, where the nal stage is performed by encapsulating
it with the third component.
Following opening of the mould, the nished part is again ejected
along with the sprues.

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3.1.10 Rotary moulds for four-component injection moulding

Two-station mould

A two-station mould can be constructed in a similar manner to that

described for a three-component mould. In the rst process step,
the pre-moulded parts are produced by the simultaneous injection of
three components. The entire mould half then rotates by 180 to the
second position. Here, the fourth component is injected around the
pre-moulded parts to form the nished parts.

Four-station mould

A four-station mould can be used to produce multi-layer plastic

parts, for example. The application of regranulated material and
resistive layers which hinder the diffusion of oxygen is possible in a
simple manner. The illustration depicts the step-by-step build-up of
a four-layer moulded part. The innermost layer is produced at the
rst station. The mould then cycles by 90 one station further. There,
the second component is injected around the rst. The mould half
then rotates on to the third station, and nally to the fourth station
for the nal production step. Once here, the outer protective layer, or
the visible layer of the moulded part, is injected onto the part. After
expiration of the cooling period, the nished multi layer part may be
demoulded from the cavity. In the actual cycle, each time the mould
is opened a completed moulded part is produced.

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3.1.11 Assembly injection moulding using rotary moulds

In the case of certain applications, components that have to be
joined together after injection moulding can be injection moulded
separately using a two-component machine and subsequently
assembled inside the mould.
These kinds of assembly tasks can be performed by means of twostation rotary moulds, for example. One possible mould concept for
assembly injection moulding is illustrated below. This is based on the
example of a cable bushing to which an internal seal is to be added.

Illustration: Example application involving a cable bushing with seal to be

internally mounted

The process

First of all, each of the two individual components are simultaneously injection moulded at the relevant station. Then, once the mould
has been opened, the rst component is transferred to the second
station by rotating the insert and is then positioned over the core of
the second component. Assembly of the seal and cable bushing is
achieved through the movement of a stamp via a core pull.
The advantage of assembly injection moulding is that it obviates the
need for any additional joining techniques and secondary production operations. Under normal conditions very expensive automation
solutions would be required in order to assemble the parts efciently
following the injection moulding process.

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Example 3.1.11: Assembly injection moulding

1. Process step
Components 1 and 2 injection
moulded

2. Process step
Mould opened

3. Process step
Insert advanced
(using hydraulic ejector)

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Example 3.1.11: Assembly injection moulding

4. Process step
Insert rotated
(indexing unit)

5. Process step
Insert retracted
(using hydraulic ejector)
Assembly process via core pull

Assembly process in detail: A sleeve operated by the core pull is used to join the sealing ring and cable bushing together
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Example 3.1.12: Assembly injection moulding

6. Process step
Insert advanced
(using hydraulic ejector)
Part is stripped

7. Process step
Insert rotated
Ejector retracted
Mould closed

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3.2 Altering the mould using internal movements inside the mould
During a process referred to as composite injection moulding, hollow
areas in the mould are rst closed and later reopened by using sliding
cores or inserts. For the production of a part consisting of two components, the rst element of the piece is injected in an initial injection step, after which a second hollow area is opened by pulling a
seal slide. Finally, the second component is injected against the rst,
whereby the completed piece is produced and can be removed from
the mould in its nal form. Another option is to change the mould
contour through internal sliding movements inside the mould, following the rst injection shot (see gure B).
A particular advantage of composite injection moulding is that production can be carried out in one mould without intermediate opening of the machine and without further transport of the pre-moulded
part. However, production is performed in a strict sequence, whereas
with rotary moulds simultaneous operations are possible.
With regard to the machine, where moulds with internal sliding
movements are used, it is necessary to have a sufcient number of
freely programmable core pulls. In relation to this, particular attention should be paid to achieving continuous safety monitoring of the
movements to avoid disruptions to production.
Composite injection moulding may be employed for two or more
components, whereby the complexity of the mould rises signicantly
with the number of the components. As in all multi-component processes, the chemical and thermal compatibility of the melts as well
as other similar process factors must be observed in the selection of
materials.

Illustration: Examples of applications involving composite injection moulding

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Processing Technology

Example 3.2: Lifting and lowering movements (composite

injection moulding)

Figure A

Figure B

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Processing Technology

3.3 Transfer by hand or robotic system

In addition to the rotation and composite injection moulding options
described, multi-component parts can also be produced by means
of mould transfer. This process involves the production of the premoulded part at a preliminary station, which, following opening of the
mould, is then transferred to another cavity or another mould using
a robotic system or the conventional method (by hand). This means
that the moulds can be kept simple, since no rotary movements or
internal movements have to be performed.
On the one hand it is possible to operate two different machines and
therefore two separate moulds at the same time. On the other hand,
using a two-component machine, it is also possible to transfer the
pre-moulded part inside the mould from one mould half to the other.
The pre-requisite for using a two-component machine is that the
cycle times for producing the components concerned must be comparable so as to ensure economical use of the two cavities.
Example application

Rollers with a running surface made from TPE which totally envelops
the outer ring can be transported inside a rotary mould, but only at
greater cost. In this case, the most economically viable method of
production is to transfer the rst injection shot to a second mould
contour by hand or using a robotic system (gure A). The main
advantages of staged moulds (such as doubling the number of cavities or bringing about a reduction in the machine clamping forces)
provide the other alternative of transferring from one stage to another
(see gure B).

Illustration: Example application involving roller

Of course, transfer can also be used for other parts that can be
relocated to the second mould contour. However, in the case of parts
with exacting tolerances or ones that are especially sensitive, it often
makes better sense to leave the pre-moulded part on the core and to
rotate the moveable mould halves.

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Processing Technology

Example 3.3: Transfer from the 1st station to the 2nd by hand
or using a robotic system

Figure A

Figure B

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Processing Technology

4. Summary

Nowadays, thanks to the ongoing further development of machine

and in particular of mould technology, a multitude of product specic
solutions involving multi-component technology are possible. These
often involve the use of fully automatic rotary moulds of various
designs. However, by way of alternative, other techniques such as
transfer or insert technologies are also being developed, so that
as many application areas as possible are catered for. This often
obviates the need for additional joining techniques or secondary
operations. The already highly advanced technology makes it
possible to achieve robust and efcient large-scale production, whilst
maintaining consistently high quality.
A special feature of multi-component technology is that it often
makes it possible to realise products with tailor-made properties and
to provide customer-specic solutions to problems in an efcient
manner. It is often possible to create components with highly resistant bonds and multi-functional properties. The multi-component
processes are also opening the way for new design possibilities as
far as components are concerned and for new methods of reducing
production costs.
In future, we can therefore expect multi-component technology to
play an even greater role. In particular, there is still a long way to go
before the potential of hard-soft combinations is fully realised, which
continues to promise a multitude of interesting possibilities in terms
of component design. Similarly, there is no doubt that a considerable
number of functional components can be produced more efciently
using assembly injection moulding as opposed to joining techniques.
Within this eld, the latest trends are aimed in particular at exploiting
the shrinkage behaviour of a material, in order to achieve targeted
separation of the components. Another eld to watch in the future is
the production of integrated circuits by combining plastics that can
be metallised with those that cannot.
Although there is no doubt that multi-component technology can now
be considered as one of the well-established specialist processes of
injection moulding, the complexity of the individual processes should
not be underestimated. It is often the problems associated with the
ner details that dictate which specic process is to be used. For this
reason, close collaboration should always be sought between the
production facility, the mould manufacturer and the machine manufacturer throughout all the stages of a project. This close collaboration should start as early as the planning phase so as to eliminate
fundamental errors that cannot be easily removed at a later date and
to ensure a maximum degree of harmony between all the components.

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