Multicomponent molding offers the possibility to manufacture multi-functional parts of a wide variety of resins and/or colors.

Major advantages:

• production of ready-to-assemble parts in a single process
• vast variety of design options in color and shape
• tailored product properties through specific material combinations, e.g. rigid-soft combinations
• integration of functions

There are two basic processes in multicomponent technology:

• multicolor molding
• multicomponent molding:
  • composite molding
  • rigid-soft combinations
  • assembly molding
  • sandwich molding (co-injection)

Differentiation by the method of transfering parts in the mold:

• rotary platen technology
• indexing plate technology
• transfer molding
• slide-cam technology

With multicomponent molding resins with different properties are combined to a single part.

Main applications are rigid-soft combinations, e.g.:

• thermoplastic material + TPE
• thermoplastic material + LSR
• thermoplastic material + elastomer
• thermoset material + LSR
• thermoset material + elastomer

Multicomponent molding - slide-cam technology (Combiform)

Process steps:

• sequential injection of two components without mold opening during the process
• hydraulic slide-cam shuts off the cavity for the second component while the first component is injected

Multicomponent molding - indexing plate technology

With the indexing plate technology, the rotating mechanism is integrated in the mold. This method is applied where the molding pattern of the preform differs from that of the second component both on the fixed mold half and on the moving mold half.

Process steps:

• injection of first component
• opening of the mold
• molded components are transferred using a so-called indexing plate which is moved outward while the mold opens, then rotated by a special drive in the mold
• closing of the mold
• parallel injection of the first and second component to finish the first part and mold the new preform

Multicomponent molding - rotary table technology

Multicomponent molding using a servo-electric or servo-hydraulic rotary table is the most popular processing method for the production of multicomponent or multicolor parts.

Process steps:

• injection of the first component
• opening of mold
• rotary table moves the preform on the moving mold half into the second position
• closing of mold
• parallel to the injection of the second component, the next preform is being molded

Multicomponent molding - transfer molding

Multicomponent molding using a transfer system is especially suitable for materials with significantly different mold wall temperatures, e.g. combinations of thermoplastic resins and LSR.

Process steps:

• injection of first component
• opening of mold
• handling system removes preforms from the first cavity and places them into the second cavity
• parallel injection of the first and second component

Utilized for the production of multicolor parts in a one-step process.

Main characteristics:

• processing of one resin type in different colors

Major applications:

• toys
• automotive parts

Main characteristics of assembly molding:

• processing of raw material without adhesive properties
• main applications:
  • components with hinged attachments

Main characteristics of Sandwich molding:

• especially suitable for thick-walled parts
• many options in material combinations, e.g. rigid-soft combinations
• use of blowing agents possible
• main applications:
  • industrial applications
  • automotive applications
  • decorative parts
  • sanitary applications

Main characteristics:

• special machine configurations with two parallel injection units to inject one component into the other

Process steps:

• both melt streams are injected sequentially
• prior to entering the mold, the melt streams are combined in a co-injection nozzle