Challenges in multicomponent injection molding

Martin Varch
Philips Austria GmbH
December 12, 2013

December 12, 2013

Challenges in multi-component injection molding

Content
multicomponent injection molding
Factors of influence
Examples
Arielle Housing
Waterfall

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Injection molding
Schematic figure

hopper

cavity
sprue

drive

nozzle

ejector

heating elements

barrel
screw

mold

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Injection molding
Screw rotates and
fills the barrel

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Injection molding
Screw rotates and
fills the barrel

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Injection molding
Screw rotates and
fills the barrel

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Injection molding
Barrel is filled and ready for injection

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Injection molding
injection

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Injection molding
injection

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Injection molding
injection

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Injection molding
Cavity is full switch over to holding pressure

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Injection molding
holding pressure

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Injection molding
Cooling and shrinking

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Injection molding
Cooling and shrinking

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Injection molding
Cooling and dosing

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Injection molding
Cooling and dosing

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Injection molding
Mold opens and throws the part out of the cavity

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Injection molding
Mold opens and throws the part out of the cavity

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Injection molding
Mold opens and throws the part out of the cavity

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Injection molding
ejecting

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Injection molding
ejecting

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Injection molding
ejecting

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Injection molding
ejecting

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Injection molding
Mold closes and process start again

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Injection molding
Mold closes and process start again

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Injection molding
Mold closes and process start again

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Multi component injection molding

Definition

A process of making a part from more than one material in the same
production process.

Different multi-component injection processes:

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two-component
co-injection
over-molded
multi-material

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Multi component injection molding

process

Mold is open, plasticization begins Injection of component A, holding

pressure and cooling time

Ejection finished 2 K part after

holding pressure and cooling
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Opening of next cavity, injection

component B

Factors of influence

Multi component
injection molding

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Examples

Arielle Housing

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Arielle Housing
Requirements

Part for water tight epilator

High gloss surface
Switching function included
No injection point(s) visible
No Parting Lines visible
Molded 3D deep-view effects
Hidden LED
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Arielle Housing
Challenges : Technology choice
1. 2 x 2 k + Pins
2. 4 k + Pins
3. ..

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Step 1: 3 k Panel
Step 2: 1 k Housing + Pins

Arielle Panel
Challenges: Out-washing effects of design-layer

1. DOE with 32 materials to get best

performance
2. Injection situation

2nd component

1st component

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1st Layer PC
2nd Layer MABS
Build a kind of jump for
2nd component

Arielle Panel
Challenges: Molding 3rd component for switch

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Arielle Housing
Challenges: Seal the 3D contour of Panel
Pin slider

slider

die (ejector side side)

Panel

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die (nozzle side)

core Housing

Examples

Waterfall
Main Cover Overmold

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Waterfall Main Cover Overmold

Requirements
Water tight
Deep view effect
Switching function included
No parting lines visible

Hidden LED

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Waterfall Main Cover Overmold

challenges
3rd Component without
additional injection unit

Additional 2-component
insert part

switch

Main Cover

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Injection point

Waterfall Main Cover Overmold

Challenges: out washing effects
no other possibilities to inject
(thick wall <7mm high gloss)

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December 12, 2013

Thank you
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December 12, 2013