Multi-Material Injection Moulding

Multi-Material Injection Moulding
V. Goodship and J.C. Love
Contents
1. Introduction 3
1.1 Multi-Component Moulding . 3
1.1.1 Co-Injection Moulding . 3
1.1.2 Bi-Injection Moulding 3
1.1.3 Interval Injection Moulding . 4
1.2 Multi-Shot Moulding 4
1.2.1 Transfer . 4
1.2.2 Core Back . 4
1.2.3 Rotating Tool 4
1.3 Over-Moulding . 4
1.4 Business Trends 4
2. Injection Moulding Basics 5
2.1 Stages of Injection Moulding . 5
2.1.1 Plastication . 5
2.1.2 Mould Filling 5
2.1.3 Packing and Solidification . 5
2.2 Differential Shrinkage and Cooling Effects . 5
2.3 Microstructure of Injection Mouldings 6
3. Material Selection 7
3.1 Material Bonding Properties . 7
3.2 General Material Properties 7
4. Multi-Component Injection Moulding 9
4.1 Co-Injection Moulding . 9
4.1.1 Material Selection for Co-Injection Moulding . 10
4.1.2 Co-Injection Moulding: Different Techniques 11
4.1.3 Sequential Injection: Single Channel Technique 11
4.1.4 Sequential Injection: Mono-Sandwich Technique 11
4.1.5 Simultaneous Injection: Two Channel Technique 12
4.1.6 Simultaneous Injection: Three Channel Technique . 13
4.1.7 Part Design and Tooling Requirements for Co-Injection Moulding 15
4.1.8 Rheology and Mould Filling: Why and How Co-Injection Moulding Works . 15
4.1.9 Immiscible Materials Research in Co-Injection Moulding 19
4.1.10 Co-Injection Moulding Applications – Case Studies 20
4.1.11 Recycling and Legislation 21
4.1.12 Discussion and Conclusions . 21
4.2 Bi-Injection Moulding 21
4.3 Interval Injection Moulding 22
5. Multi-Shot Moulding . 22
5.1 Machine Technology . 23Multi-Material Injection Moulding
5.1.1 Injection Unit Configurations . 23
5.1.2 Plastication Design . 23
5.1.3 Machine Type . 23
5.2 Core Back Moulding . 24
5.3 Rotating Tool Moulding 25
5.4 Transfer Moulding 25
5.5 Multi-Shot with a Single Injection Unit . 26
5.6 Material Selection for Multi-Shot . 26
5.6.1 Material Properties . 26
5.6.2 Material Process Order . 27
5.6.3 Using Thermoset Materials 27
5.6.4 Liquid Silicone Rubber (LSR) . 27
5.6.5 Thermoplastic Elastomers (TPEs) 27
5.7 Multi-Shot Moulding Applications – Case Studies . 28
5.7.1 Trio Knob . 28
5.7.2 Stanley Screwdriver . 29
5.8 Limitations to Multi-Shot Moulding 29
6. Over-Moulding . 30
6.1 Insert Moulding . 30
6.2 Lost Core Moulding 30
7. The Future? 31
Additional References . 31
Abbreviations and Acronyms . 32
Abstracts from the Polymer Library Database 33
Subject Index
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