Inox Cast Multi-shot Injection Molding

Inox Cast is one of the best manufacturers and distributors of multi-shot injection molding. We have the widest range of this product available for affordable prices. We designed this product to offer you better functionality and savings.

Inox Cast produces multi-shot injection molding that processes multiple resin or materials into a mold to create multiple components. It has multi-colored parts, soft handle inserts, an aerospace dashboard, assemblies with movable components, and many more.

With our multi shot injection molding, you will have high-quality products with high accuracy and dimensional tolerance. Your products will have competitive textures, colors, and prices.

Inox Cast multi shot injection molding is perfect for multi-color, complex, and multi-material plastic products. Our product offers premium quality, improves efficiency, and cost-efficient.

Since 1997, we have enough gained experienced in manufacturing the multi-shot injection molding, expert in die-casting, plastic mold, R&D prototype designing, assembly, and machining of finished products.

We also offer premium surface finishing, powder coating, chrome plating, painting, screen printing, and ED coating. Our multi shot injection molding has wide applications. It can be used for household appliances, consumer electronics, medical equipment, automotive machines, and telecommunications.

Inox Cast is composed of 1, 000 workers operating in a plant area that covers 32, 000 square meters. We are equipped with highly skilled senior managers and technical personnel.

We have the latest machining equipment and machine tools. We have high rpm CNC, Mitsubishi EDM, Charmilles EDM, and grinder. Inox Cast guarantees you that our products passed the final CMM inspection.

In Inox Cast, you can find excellent and durable multi-shot injection molding with innovative designs. We can also customize this product with your chosen requirements in sizes and specifications.

Allow us to be your trusted multi-shot injection molding manufacturer. Send us your inquiries today!

Multi Shot Injection Molding: The Ultimate Guide

If you are having any question on multi shot injection molding – this guide provides all valuable information you are looking for.

So, keep reading to learn more.

1.  What Is Multi Shot Injection Molding?

This is the process where you will inject two or more types of plastic materials or colors simultaneously into one mold to form a single component.

Furthermore, you can use this process with other materials other than plastic like metals that contain plastics.

multi shot injection molding

A multi-shot injection molding machine contains many injectors where you will fill each one of them with the suitable material.

Also, a multi-shot can have 2 as the minimum and 6 as the maximum number of injectors.

2.  What Is The Operational Principle Of A Multi Shot Injection Molding?

The first step entails forming the mold that you will use when creating the components.

A multi-shot injection molding machine has many molds and this is influenced by the number of injectors.

At every phase, you will add more material until you complete the final material injection.

For instance, a three-phase multi-shot injection molding process has a machine with three injectors.

Every injector connects to the material you will be using in the molding process.

This means that the mold you will use to create the component will have three separate designs.

The first mold cut will occur when you inject the first material once you close the mold cavity.

Afterward, the machine will automatically relocate the material to the second mold once the first one cools.

The mold then closes and the materials will enter the machine via the first and second molds.

Also, you will add more material substance to the material within the first mold during the second mold phase.

After these materials cool, the mold will open and the multi-shot injection molding machine will move the materials once more.

This occurs as the second mold moves to the third mold whereas the first mold relocates to the second mold.

In the final phase, you will inject the third material as it directs itself to the third mold to make the final part of the product.

Furthermore, you will inject the molten material into both the first and second mold.

Once all materials cool, the mold will open and the multi-shot injection molding machine will automatically eject the final product.

This process is an overview of the multi-shot injection molding process and can vary considerably.

The variations come about depending on the type of multi-shot injection molding machine you are using in your application.

3.  What Are The Advantages Of Using Multi Shot Injection Molding?

There are many advantages to using a multi-shot injection molding process and they include the following:

• Minimal production cost

A multi-shot injection molding process allows you to make the final product using one machine as opposed to several machines.

• Minimal secondary processes

Multi-shot injection molding allows you to add several elements during the molding process.

Examples of these elements include logos, graphics, texts, etc.

• Minimal production cycle durations

The time you need to make parts with a multi-shot injection molding process is minimized.

Also, you can automate the production process to attain a fast output.

• Enhanced productivity

The output level of a multi-shot injection molding will be higher because of a reduction in the production cycle times.

• Improved quality

Because you will be making the part in one machine, the final product will have good quality.

This is because you are using fewer production phases.

Also, the clean and smooth material transition offers an efficient production process.

When you lower the need for operations, you reduce the risk of errors occurring thus improving the overall product quality.

• Minimize assembly operations

Multi-shot injection molding allows you to make the final product with several materials in one single process.

This means there is no need to have laborers put all these parts together after the molding process.

4.  What Are The Applications Of A Multi Shot Injection Molding?

There are several applications of a multi-shot injection molding and they include:

• Automotive industries
• Life science
• Consumer products
• Safety or special applications
• Medical devices

5.  What Are Examples Of Parts That You Can Make Using Multi Shot Injection Molding?

There are several parts you will find in a multi-shot injection molding device and they include the following:

Hopper

It is in this part that you will place the plastic ingredients that you will use during the multi-shot injection molding process.

Heaters

This part is suitable for increasing the temperature of the multi-shot injection molding system.

This enables you to make products that have a good finish and high quality.

The heaters will melt the plastic ingredients polymers you will be injecting into the system.

Screw Motion

This part will push the plastic ingredient materials in forward momentum.

Nozzles

This part is responsible for allowing the molten plastic material into the mold cavity once it attains a molten state.

Clamping Device

This part will clamp and hold the tool tightly in place.

Injection Device

This part is responsible for injecting the plastic into the mold.

Drive System

This part will ram the mold within the cavity.

Hydraulic System

This part will ram the mold through the press.

Cooling Channels

This part is responsible for cooling the molten plastic material into a solid nature.

Extraction Pins

This part operates like a split mold and allows you to remove the shape formed for further processing.

6.  What Are The Disadvantages Of A Multi Shot Injection Molding?

A multi-shot injection molding has some disadvantages and they include the following:

Compatibility

Not all plastics you are using will be compatible with one another.

For this reason, you need to evaluate the compatibility of these plastic materials before you use them in the molding process.

When you use plastics that are not compatible with one another, the final product will not bond.

This means you need to research the chemical composition of the materials you are using before you start the process.

Shrinkage Rate

Make sure you have a minimal shrinkage rate between the plastics you are using for multi-shot injection molding.

If you have a large shrinkage rate, the final product will warp as the bonding strength is affected.

Shape

Make sure the final product has a shape that is not too complex.

7.  How Should You Select Materials To Use In A Multi Shot Injection Molding?

Different plastic materials have different chemical compositions and this will influence their compatibility.

Therefore, make sure the materials you want to use for multi-shot injection molding are compatible as it will enhance their durability.

Furthermore, the coefficient of thermal expansion and covering materials need to be alike.

Also, ensure the shrinkage rate of the base materials and the covering materials are as similar as possible.

In addition, ensure you have a higher HDT level for the base materials.

Finally, do not combine amorphous plastic materials and semi-crystalline materials during multi-shot injection molding.

8.  What Parameters Should You Adhere To When Designing For A Multi Shot Injection Molding?

Some of the parameters worth confirming include the following:

Draft Angle

This is an important angle in multi-shot injection molding as it will determine how mold components attach when you rotate them.

During the first injection, the component should attach itself to the moving mold.

However, in the second injection, it should attach to the ejector side.

Furthermore, make sure the planes have broad release slopes as it will inhibit any scratches from happening during mold closure.

Inner Bonding Surface

Here are some factors that will determine the bonding strength between the base materials and the cover materials:

1. Compatibility of the materials
2. Sequence of molding
3. Temperature of the molding process
4. Surface design bond

Wall Thickness Uniformity

Make sure the multi-shot injection molding process conforms to smooth corners, better transitions, and uniform wall thickness.

Mating Surface Appearance

Make sure the mating surface cosmetics provide suitable bonding strengths.

If not, it might cause the product to flake, have burrs and experience rolled and flying edges.

Stepped and fluted are the most popular mating surface appearances.

Difference In Weight

During the design process, make sure the cover materials and the base materials almost have similar weights.

This is because the weight difference will affect the injection pressure, and molding cycles, among other things.

9.  How Does Multi Shot, Multi Component, And Over-Molding Injection Molding Compare?

Here is how these compare:

Multi-shot Injection Molding

This is also known as sequential injection molding.

Here, you will create several layers from the starting axis all from the initial mold.

For instance, you will inject warm and heated plastic materials into the mold cavity one after another in a predetermined sequence.

This will form layering elements between the different materials.

It will also maintain a high energy interaction at the boundaries of the materials.

multi injection molding

This proves vital since it means that the internal layers have stronger bonds.

On the contrary, this is not true when you apply other layers to a component that has already cooled like in over-molding.

There are several applications and multi-shot injection molding is suitable when you need varying molds between layers.

Multi-component Injection Molding

This is also known as co-injection molding.

Multi-component injection molding entails simultaneously inserting several molten materials.

This is opposed to injecting one viscous material as an extra layer relative to another layer within the product.

multi component injection molding

For this reason, multi-component injection molding forms sandwich-like features where the different materials mold around one another.

Also, you can inject the materials concentrically using a similar mold relative to the center part.

Furthermore, you can also inject the materials regionally through gates that are in different locations.

Over Molding

This is the effective use of layering techniques in polymer usages.

Over molding entails using viscous resin to add extra shape layers and features to a pre-existing part.

For instance, you can use resin as a polymer after you heat it to temperature levels above its glass transition temperature.

overmolding

Also, the component that you are adding to the resin is usually injection molded.

Furthermore, it may be close to its glass transition temperature.

Over molding is suitable for use when you desire layers with different configurations around one central core feature.

10.  What Kind Of Plastic Material Can You Use In A Multi Shot Injection Molding?

Manufacturers of plastic components mainly use thermoplastics during multi-shot injection molding.

Thermoplastics are a polymer that will melt in high-temperature conditions and solidify in cool temperature conditions.

Furthermore, you can heat and cool thermoplastics severally before it starts to degrade rendering them not useful in the molding process.

This is however not true with thermoset plastic materials which will burn if you reheat them.

Also, you will see thermoplastics in the form of plastic pellets for multi-shot injection molding.

In addition, you can mix the plastic pellets with other substances such as:

• Coolants
• Glitter
• Recycled materials
• Other specialty additives

Here are some popular thermoplastics you can use in multi-shot injection molding:

Polyethylene

This thermoplastic material is versatile and finds its application in several multi-shot injection molding processes.

Furthermore, polyethylene has suitable characteristics that include the following:

1. High levels of ductility
2. Impact resistance
3. High tensile strength
4. Low moisture absorption
5. Recyclability

Polycarbonate

These are transparent types of thermoplastic you will use in multi-shot injection molding.

Furthermore, polycarbonates are resistant to impact and can withstand high plastic deformations without cracking or breaking.

Several manufacturers prefer polycarbonate when making eyewear lenses, mobile systems, and medical devices.

Also, you can use polycarbonate to manufacture bullet-proof glass.

Nylon

This thermoplastic material has suitable electrical characteristics and is also tough.

Nylon finds its application in a broad range of applications such as industrial parts and sports equipment.

Polypropylene

This type of thermoplastic is flexible.

Polypropylene has suitable chemical resistance.

Also, it will not leach into food items thus making it ideal for the manufacture of eating utensils or food containers.

Acrylonitrile Butadiene Styrene [ABS]

This is a rigid yet lightweight material that you can use in multi-shot injection molding.

Furthermore, it is a popular thermoplastic material for use in injection molding.

11.  What Are Some Types Of Multi Shot Injection Molding Machines?

These include:

Hydraulic Multi-shot Injection Molding

This is the oldest form and uses hydraulic oils to generate pressure during the process.

The oil sits within the hydraulic motor and will assist in rotating the screws.

Some benefits include:

1. They are cost-effective and can fulfill suitable injection rates
2. Also, they have suitable ejection capacities due to their potent nature
3. Since they are abundant, it is easy to find spare parts
4. It can handle suitable product amounts because of its large shot size
5. The clamping force it offers makes it able to provide precise designs
6. Modern advancements like gas accumulators make the machine faster

hydraulic multi shot injection molding

Some limitations include:

1. There are possibilities of leaks happening thus expect to frequently clean the machine
2. Also, due to the leakages, expect to clean the work area frequently
3. The machine consumes more power and this can be a concern for many users
4. It poses environmental concerns due to the noise pollution it produces

Electrical Multi-shot Injection Molding

This machine employs high-speed motor servos, is simple to use, and has more advancements than the conventional hydraulic machine.

Also, it is cost-efficient because of the speed and comfort it offers.

Furthermore, it requires less maintenance and you can set pressure and energy requirements as per your needs.

electrical multi shot injection molding

Some benefits include:

1. The machine is effective and operates fast meaning you can make several products within a short time
2. It will maintain the workspace hygiene since it uses no fluids during operation
3. The machine is environmentally friendly as it produces minimal sound
4. Since you can control output levels digitally, it will use less power
5. It has minimal maintenance cost since it requires less maintenance
6. They can produce molded parts with high precision

Some limitations include:

1. The machine produces a small clamping force than hydraulic machines
2. It is more expensive than hydraulic machines
3. During problems, issues may arise because spare parts are scarce

Hybrid Multi-shot Injection Molding

This machine incorporates both electrical and hydraulic multi-shot injection molding.

It provides more flexibility, energy efficiency, and accuracy.

hybrid multi shot injection molding

Some advantages include:

1. It will rarely heat up thus requiring minimal maintenance
2. It offers excellent output since you can flexibly control the output of energy levels
3. The machine attains high-quality product output and saves you money
4. It operates at high speeds thus you can meet your targets

Some limitations include:

1. Assembly of the machine needs you to rely on the user’s requirements
2. Also, you need to train your operators enabling them to use hydraulic and electrical units
3. It has a complex design meaning the manufacturer is the one able to maintain the machine

12.  What Should You Consider When Selecting A Multi Shot Injection Molding Machine?

These include:

• The dimension of the final product
• Model of the multi-shot injection molding machine
• Type and quality of plastics
• The type of mold, weight, design, height, etc.
• Molding needs, quality of products, and production rate

13.  What Are Some Common Defects You May Encounter During Multi Shot Injection Molding?

These include:

• Albinism
• Vacuum holes
• Short shot
• Flying edge split materials
• Flow marks
• Mold adhesions
• Shrinkage distortion
• Bubbles
• Weld marks
• Surface blowholes
• Charred black strips
• Silver back wires

14.  What Factors Will Affect The Cost Of Multi Shot Injection Molding?

These include:

• Tooling cost
• Material cost
• Quality requirements
• Production cost
• Redesign factors
• Number of parts you need
• Design complexity

For any inquiries or questions on multi shot injection molding parts, contact us now.