What are The Differences Between Two-color Injection Molding and in Mold Injection Molding?
What are the differences between two-color injection molding and in mold injection molding, and what are the key considerations for structural design?
In injection molding technology, two-color injection molding and in mold injection molding are two common and distinctive process methods. They not only have significant differences in production efficiency and product quality, but also pose different requirements and challenges in structural design. This article will delve into the technical differences between two-color injection molding and in mold injection molding, as well as the key points to be noted in structural design.
Double color injection molding, as the name implies, is to use two or more colors of plastic materials in the same mold at the same time for injection molding, and achieve the effect of multiple colors on the product surface through one molding process. This process requires the injection molding machine to have a dual barrel and dual mold cavity structure, which can complete the simultaneous injection and bonding of two materials in one injection molding cycle.
In contrast, in mold injection molding (also known as two-step injection molding) adopts a staged injection molding method. Firstly, a component made of one material is molded on an injection molding machine, and then the component is inserted into another set of molds as an insert, followed by injection of plastic of the second material. Through this method, multiple materials or colors can be combined.
Double color injection molding, due to the use of one-time molding technology, can significantly improve production efficiency, reduce production cycles and labor costs. However, the design complexity and manufacturing cost of two-color injection molds are relatively high, requiring two sets of front molds and fine channel design to ensure the smooth combination of the two plastic materials.
Although the process of in mold injection molding is relatively simple, its production efficiency is low because it requires staged injection molding and mold replacement. However, its mold cost is relatively low, making it more suitable for producing products with small batch sizes or strict cost control.
1.Two color injection molding
·Mold design: Two color injection molds require precise design to accommodate the feeding and forming requirements of two or more plastic materials. The mold structure should fully consider the size, shape, color, and surface requirements of the product, as well as the fluidity and color distribution of the plastic material. The design of the flow channel is particularly important to ensure that the two colors of plastic can be smoothly injected and form a good bond.
·Material selection: Choose suitable plastic materials based on the design requirements of the product and the final application environment. Different materials have different melting points, elasticity, durability, and other characteristics. Choosing the appropriate material is crucial to ensuring product quality.
·Injection molding process control: During the injection molding process, it is necessary to accurately control the injection volume, pressure, speed, temperature, and other parameters of the plastic. These parameters directly affect the quality and appearance of the product.
·Mold separation and positioning: The internal structure of the injection mold needs to be designed with separation and positioning devices for two types of plastic materials to avoid color mixing or contamination. At the same time, the design of the injection system and cooling system also needs to be more detailed to ensure that the two plastic materials can be injected separately and stably molded.
·Product positioning: When placing the insert into the mold, it is necessary to set positioning points or limit devices to prevent the insert from shifting or deforming during high-pressure injection.
Material compatibility: When the first layer is made of metal or other non plastic materials, its bonding and peeling properties with plastic need to be considered. Usually, it is necessary to enhance the bonding force by designing structures such as dovetail buckles and circular holes.
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