2-Shot Molding

2-Shot injection molding, also known as 2K or multi-component molding, is a fairly recent method of manufacturing compared to its predecessors. At its most basic, multi-shot injection molding combines two or more materials in a single cycle of the machine, but there are a variety of ways that we can achieve that here at DPI.

Two-Shot Molding

Two-shot over-molding involves molding one type of plastic over another within a single mold. There are several different combinations:

• A soft-touch material over a harder substrate

• A clear window in an opaque substrate

• Two different colors of the same thermoplastic material

Two-shot molding offers several advantages over traditional methods that would require multiple molds, presses, and cycles. Not only is it more accurate, it is also a much faster and more precise method, throughout the process, the part never has to leave the mold or be moved from one machine to another. In addition, the chemical bond between the different plastics is much greater with true multi-shot machines, leaving less room for damage due to a weaker bond.

Multi-Process Molding

We use Multi-Process Molding to mold two different parts, each made from different materials, all within a single mold tool. Typically, multi-process molding is best for parts that will be used together in something like a welded assembly. Or we use the process to produce different parts from the same material, avoiding the inherent issues associated with family tools. By using a different injection unit for each different part, we can provide the perfect injection profile for each part, resulting in superior quality. Multi-process molding has provided our customers with significant cost savings.

In-Mold Assembly

In-Mold Assembly is similar to Multi-Process Molding, only we utilize mechanisms within the mold to assemble the different parts and produce an assembled unit each cycle. Not only are we realizing the benefits of molding two different parts within a single mold, we are also stripping out the labor costs associated with the traditional post mold assembly process.

Sandwich Molding

Sandwich Molding, sometimes called "Co-Injection", is a process where one material is injected through the liquid melt of another material forming a core material with a skin of the other material on the outside. This is commonly used for cost savings where a product has a lesser expensive core material with a more expensive skin material. Also a foamed inner core with a more cosmetic outer skin can result in weight decrease of the final product.

Interested in learning more?

Distinctive Plastics, Inc. (DPI) is here to be your partner for multi-shot injection molding as well as other advanced molding solutions. Do not hesitate to contact us today with any questions or to request a quote.