Challenges in multi-

component injection molding

Martin Varch
Philips Austria GmbH
December 12, 2013

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 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
nozzle drive
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:

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 Opening of next cavity, injection

holding pressure and cooling component B

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 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 Step 1: 3 k Panel

2. 4 k + Pins Step 2: 1 k Housing + Pins
3. ..

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

1. DOE with 32 materials to get best 1st Layer PC

performance 2nd Layer MABS

2. Injection situation Build a kind of jump for

2nd component

2nd component

1st component

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 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)

die (nozzle side)

Panel
core Housing

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 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 2-component

additional injection unit 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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 Thank you

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