Process

Co-injection molding is a process in which two or more different polymers are laminated
together by injection molding. These polymers may be identical except for color or hardness, or
they may be of different polymer types. When different polymers are used they must be
compatible (i.e., weld together) and melt at approximately the same temperature.
The term co-injection can denote different processes, such as
sandwich construction, double shot injection, multi-shot injection or
structural foam construction. Whatever its designation, a sandwich
configuration has been made in which two or more thermoplastics
are laminated together to take advantage of the different properties
each contributes to the structure. Most commonly, the skin material
is solid while the core material contains a blowing agent. However,
any combination of foamed and/or unfoamed skin and core is
possible. For heavy walled parts, cooling time may be substantially
reduced by running the skin material at a higher melt temperature for a smooth surface and the
core material, which essentially determines cycle time, at a lower melt temperature.
There are three basic co-injection molding techniques -- one-, two- and three-channel. In the
one-channel system, the plastic melts are shot sequentially into the mold by shifting a valve.
Because of the flow characteristics of the melt and the tendency of the skin material to adhere to
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the cooler mold surface, a dense solid skin is formed. Thickness of the skin can be controlled by
varying the injection rate, melt temperature and flow compatibility of the two materials.
In the two-channel system, sequential or simultaneous injection of both the skin and core
materials is possible. This permits control of the skin thickness, especially in the gate areas on
both sides of the part. In this type of molding, it is best if profile injection is used. The use of
profile injection permits greater control of the surface appearance. The machine can be profiled
by the number of velocity settings a machine has. The velocity can be varied from 0.1 to 4
inches per second.
The three-channel system allows simultaneous injection with a direct sprue gate. The skin
thickness may be influenced on both sides of the part. With this system, the foamed core
progresses farther toward the end of the flow path than that of the one- and two-channel
techniques. Parts can also be designe d to be lighter in weight.
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Advantages Disadvantages
Material cost savings and lighter
weight parts
Machine costs are 25 to 30% higher
than for standard injection equipment
Two different or alike materials can be
shot simultaneously into the mold
Good tool makers familiar with
tooling requirements are difficult to
find in some areas
Some co-injection machines can be
adapted for gas assist, which allows the
machine to perform dual functions
Material viscosities must be very
similar or part can easily be core-rich
or skin-poor
Allow an outlet for regrind usage on
internal core
Sometimes difficult to obtain
technical support for equipment
problems
Market Segments
Market Applications
Automotive
Fender skins
Interior components
Plumbing
Handles and faucet components
Toilet seat
Appliance
Door panels
Handles
Housewares
Cups
Thermos bottles
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Equipment Suppliers
Battenfeld of America, Inc. Krauss Maffei Corporation
31 James P. Murphy Highway 7095 Industrial Road, P.O. Box 6270
West Warwick, CT 02893 Florence, KY 41022-6270
Contact - Ed Matola, VP Sales and Marketing Contact - Virginia Mattmann, Sales Coord.
(401) 823-0700 (606) 283-0200
Cincinnati Milacron / Ferromatik Milacron Nestal Machinery, Inc.
4701 Marburg Avenue 72 Lake George Street
Cincinnati, OH 45209 Devens, MA 01433
Contact - Robert Hare, General Manager Contact - Dan Morris, Sales Manager
(49) 7644-780 (overseas) (508) 772-5100
Engel Canada Nissei America, Inc.
545 Elmira Road 1480 N. Hancock Street
Guelph, Ontario Anaheim, CA 92807
N1K 1C2 Contact - Rick McGranahan, Sales Manager
Contact - Kurt Fenske, VP Sales and Marketing (714) 693-3000
(519) 836-0220
NOTE:
The following supplier specializes in multi-gate systems
for co-injection and two-shot molding.
Kortec, Inc.
3 Crafts Road
Gloucester, MA 01930-2135
Contact - Paul Swenson
(508) 283-6543
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Process
The two-shot (or two-color) process requires a machine with two independent injection units,
each of which shoots a different material. The first material is injected through a primary runner
system, as in a normal injection molding cycle. During this injection, the mold volume to be
occupied by the second material is shut off from the primary runner system. The mold is then
opened and the core plate rotated 180. The mold is again closed and the second runner system
connected to the volume to be filled. After sufficient part cooling, the mold is opened and the
part is ejected. The injection of the first material through the primary runner system and the
second material through the secondary runner system occurs at the same time.
This process also enables two dissimilar materials to be mechanically bonded. If the first shot
totally solidifies before the second material is injected, a crack will usually form between the
two, due to the differential shrinkage.
The two-shot process can also be accomplished with an indexing system (a round table rotating
around a horizontal axis) with a primary and secondary station. While the first injection is
accomplished at station #1, the second injection is accomplished at station #2. Each injection
station is run by an independent injection unit. This allows injection speeds and pressures to be
controlled for each material being utilized. The two-shot or two-color process can also be
performed by either indexing the mold in the machine or with a rotary table.
Advantages Disadvantages
Cycle times are fairly fast
Dual injection unit needed either
vertical or 90 from main injection unit
(requires more floor space)
Not very labor-intensive Mold costs are somewhat high
Excellent for high volume production
Good mold builders may be hard to find
in some areas
Molding flexibility of two rigid materials,
two soft ones or a combination
Capital for machine is approximately
20% higher than for standard equipment
Single mold produces finished part
Sometimes where barrels are in tandem,
mold balancing is much harder and
tools end up being 6, 10 or 12 cavity
Machine can be utilized for standard
molding or two-shot
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Market Segments
Market Applications
Automotive
Knobs
Interior panels
Under-the-hood covers
Consumer
Toys
Industrial grips
Hand and power tools
Appliance
Handles
Interior panels
Sweeper components
Cooking utensils
Medical
Syringe components
Metering pump components
FDA
Food containers
Toothbrushes
Sealing devices
Equipment Suppliers
Any machine supplier will build a two-shot machine. Listed here are true two-shot machine
manufacturers.
Battenfeld of America, Inc. Krauss Maffei Corporation
31 James P. Murphy Highway 7095 Industrial Road, P.O. Box 6270
West Warwick, CT 02893 Florence, KY 41022-6270
Contact - Ed Matola, VP Sales and Marketing Contact - Virginia Mattmann, Sales Coord.
(401) 823-0700 (606) 283-0200
Cincinnati Milacron / Ferromatik Milacron Nestal Machinery, Inc.
4701 Marburg Avenue 72 Lake George Street
Cincinnati, OH 45209 Devens, MA 01433
Contact - Robert Hare, General Manager Contact - Dan Morris, Sales Manager
(49) 7644-780 (overseas) (508) 772-5100
Engel Canada Nissei America, Inc.
545 Elmira Road 1480 N. Hancock Street
Guelph, Ontario Anaheim, CA 92807
N1K 1C2 Contact - Rick McGranahan, Sales Manager
Contact - Kurt Fenske, VP Sales and Marketing (714) 693-3000
(519) 836-0220
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Process
A solid preform (plastic or metal) is placed into a mold and the polymer is shot around it.
Preforms are usually produced with a plain exterior, without serrations or knurls. They are
bonded by melting of the outer skin, which creates a weld between the insert and outer skin
material. The generation of a satisfactory weld requires that the preform material and
overmolded polymer be compatible. Normally, a mechanical means, such as flow through slots,
enhances the bonding.
When two materials are not of the same polymer type and thus incompatible, it is necessary to
use an adhesive on the preform surface prior to molding the second material. Utilizing
adhesives, suitable bonding can be achieved. If the preform is metal, it will require cleaning and
degreasing prior to applying adhesives.
Advantages Disadvantages
Machine costs are in mid-range
Most insert molding is run on shuttle type
equipment
A good bond can be achieved
when like materials are used
Labor-intensive loading and loading of
tool
Low cost tooling
Most crystalline materials must set for 24
hours prior to insert molding
Best utilized when molding
couplings on hoses or wire
connectors
Dissimilar materials will require
secondary operations and equipment,
adhesives and ovens
Inserts must be handled carefully or
adhesion issues may occur
Cycle times are relatively long
Unless dedicated press for each step,
down time for mold changeovers
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Market Segments
Market Applications
Appliance
Hose end connectors
Fill tubes
Automotive
Wire and vacuum connectors
Air ducts
Audio Speaker surrounds
Equipment Suppliers
Battenfeld of America, Inc. HPM Corporation
31 James P. Murphy Highway 820 Marion Road
West Warwick, CT 02893 Mt. Gilead, OH 43338
Contact - Ed Matola Contact - Randall Parker
VP Sales and Marketing (419) 946-0222
(401) 823-0700
Cincinnati Milacron / Ferromatik Milacron Krauss Maffei Corporation
4701 Marburg Avenue 7095 Industrial Road, P.O. Box 6270
Cincinnati, OH 45209 Florence, KY 41022-6270
Contact - Robert Hare, General Manager Contact - Virginia Mattmann, Sales Coord.
(49) 7644-780 (overseas) (606) 283-0200
Engel Canada Van Dorn Demag Corporation
545 Elmira Road 11792 Alameda Drive
Guelph, Ontario Strongsville, OH 44136
N1K 1C2 Contact - David Walters, National Sales
Contact - Kurt Fenske, VP Sales and Marketing Manager
(519) 836-0220 (216) 238-8960
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