two-shot molding

Two Shot Molding

 Mastering Two Shot Molding: A Revolution in Plastic Injection

Two Shot Molding or two shot injection molding has revolutionized the world of plastic injection molding. This advanced manufacturing process offers a level of precision and versatility that is unmatched by traditional injection molding methods. In this comprehensive guide, we’ll delve into the intricacies of Two Shot Molding, exploring its processes, applications, benefits, and challenges. Whether you’re a seasoned industry expert or a curious novice, this article will provide valuable insights into the world of Two Shot Molding.

Two-Shot Molding: Colorful Solutions for Plastic Molding Parts

Two-Shot Molding (also called 2k mold, double injection molding) are a cost-effective method to produce plastic parts with two or more colors moulded at the same time, such as radio control buttons or dashboard faceplates.

Two-Shot molding is a relatively new, rapidly growing technology. It is replacing older, two-step systems, eliminating a secondary process to add logos, graphics or text. New computer technology and advanced materials have promoted the growth of the two-shot process.

The two-shot process first injects one color material into the mold, then injects the second color around or over the first color. There are also multi-shot processes for parts with more than two colours.

two shot injection molding

two shot injection molding

The Two Shot Molding Process

Two Shot Molding is a multi-step process that involves injecting two different materials into a single mold to create a finished part with multiple colors or properties. Let’s break down the process into its key components:

  1. First Shot: The “First Shot” in Two Shot Injection Molding is a crucial step in the two-step injection molding process. This initial injection is where the primary material, typically a rigid thermoplastic, is injected into the mold cavity to create the foundational structure of the part.

    Here’s a more detailed look at the “First Shot” stage:

    1. Material Selection: The selection of the primary material is vital. It should possess the desired mechanical and structural properties required for the finished part. This material serves as the core or substrate upon which the second material will be added.

    2. Mold Preparation: The mold used in Two Shot Molding is designed to accommodate both the “First Shot” and the “Second Shot.” It is crucial to ensure that the mold is appropriately prepared for the first injection. This includes proper alignment and clamping to prevent any material leakage.

    3. Injection: The chosen primary material is heated to its melting point and then injected into the mold cavity. This injection is carried out with precision, ensuring that the material fills the mold cavity uniformly to create the primary structure of the part.

    4. Cooling and Solidification: After the injection, the mold cools and solidifies the primary material. The cooling time and temperature are critical factors in achieving the desired material properties and dimensional accuracy.

    5. Mold open with no ejection: Once the first shot material has sufficiently cooled and solidified, the mold opens, and the core side (moving half) turn over 180 degree to prepare the second shot. This part is known as the “preform” or the “substrate.”

    The “First Shot” sets the stage for the second injection. It determines the part’s core structure, mechanical properties, and the areas where the second material will be added. The precision and accuracy in this step are essential to ensure a successful Two Shot Injection Molding process.

  2. Second Shot: The “Second Shot” is the second and final step in the Two Shot Molding process. In this stage, a different material or same material but different color is injected into the mold to complement or enhance the part created in the “First Shot.” The “Second Shot” provides additional colors, textures, properties, or features to the final product, creating a part with multiple materials or properties in a single mold.

    Here’s a closer look at the “Second Shot” phase:

    1. Material Selection: For the “Second Shot,” a different material is selected, which complements or contrasts with the material used in the “First Shot.” The choice of material depends on the desired characteristics of the final part, such as color, texture, or additional functional properties.

    2. Mold Preparation: The same mold used for the “First Shot” is used for the “Second Shot.”  two shot injection molding including two molds together to be two shot mold. Proper alignment and clamping of the mold are crucial to ensure that the second material is injected accurately and bonds effectively with the first material.

    3. Injection: The second material is heated to its melting point and injected into the mold cavity. This injection must be precise to ensure that the material fills the designated areas of the mold, forming the desired features or properties. The coordination between the “First Shot” and the “Second Shot” is critical to achieve accurate material distribution and bonding.

    4. Cooling and Solidification: After the “Second Shot” is injected, the mold cools and solidifies the second material. The cooling time and temperature are carefully controlled to achieve the desired material properties and ensure a strong bond between the first and second materials.

    5. Ejection: Once the “Second Shot” material has cooled and solidified, the mold opens, and the finished part is ejected from the machine. The final product now features the combination of the “First Shot” material and the “Second Shot” material, creating a multi-material, multi-property part.

    The “Second Shot” injection adds complexity and versatility to the manufacturing process, allowing for the creation of parts with diverse colors, textures, functional properties, and more. It is essential to ensure that the materials used in the “First Shot” and “Second Shot” are compatible and that the injection process is well-controlled to achieve the desired aesthetics and performance in the final product. The result is a finished part that can meet the requirements of a wide range of industries, from automotive and consumer electronics to medical devices and beyond.

Injection Molding Machines for Two Shot Molding

To execute Two Shot Molding effectively, specialized injection molding machines are used. These machines have two injection units, allowing for the sequential injection of different materials. The coordination between the two injection units is crucial to achieve accurate and consistent results. Modern machinery offers sophisticated control systems, ensuring precise material distribution and minimizing waste.

Materials Used in Two Shot Molding

Selecting the right materials is a critical aspect of Two Shot Molding. The choice of materials depends on the desired characteristics of the final part. Common material combinations include:

  • Thermoplastic and TPE: Combining a rigid thermoplastic with a soft thermoplastic elastomer (TPE) can create parts with both structural strength and flexibility.

  • Two Thermoplastics: Using two different thermoplastics can yield parts with varying colors, textures, or properties.

  • Thermoplastic and Overmold: Overmolding a thermoplastic with a second material can enhance grip, aesthetics, or functionality.

  • Multi-Color Combinations: For parts requiring intricate designs or color variations, using different colored thermoplastics is a common choice.

Advantages and Benefits of Two Shot Molding

The Two Shot Molding process offers several advantages and benefits, making it a preferred choice for manufacturers:

two shot molding

2k molding

Improved Product Design and Aesthetics

Two Shot Molding allows for the integration of multiple materials, colors, and textures within a single part. This versatility enhances product aesthetics and design options, making it ideal for consumer products and complex components.

Cost Savings

While the initial investment in Two Shot Molding equipment may be higher, the process can lead to substantial cost savings in the long run. It reduces the need for secondary processes such as assembly and bonding, minimizing labor and material costs.

Reduced Assembly Steps

As mentioned, Two Shot Molding eliminates the need for secondary assembly steps, simplifying production and reducing the risk of errors. This streamlines the manufacturing process and accelerates time-to-market.

Enhanced Material Compatibility

By combining materials with complementary properties, Two Shot Molding offers the advantage of improved material compatibility. This is especially beneficial in applications where different materials need to work together seamlessly.

Environmental Considerations

Reducing waste is a significant environmental benefit of Two Shot Molding. It minimizes material scrap and excess packaging associated with traditional manufacturing processes, contributing to sustainability efforts.

Applications of Two Shot Molding

The versatility of Two Shot Molding extends to various industries:

Automotive Industry

In the automotive sector, Two Shot Molding is used to create components with both functional and aesthetic requirements. It’s commonly employed for creating grip-enhancing surfaces on steering wheels, gearshift knobs, and interior trim pieces.

Consumer Electronics

Consumer electronics benefit from the aesthetic advantages of Two Shot Molding. It’s used to produce products with visually appealing designs and tactile comfort, such as smartphone cases and remote control buttons.

Medical Devices

Two Shot Molding ensures the precision and functionality required for medical devices. It’s employed in creating components like ergonomic surgical tools and drug delivery devices.

Packaging

In the packaging industry, Two Shot Molding is used for designing containers with built-in seals, grips, or color variations. This simplifies the packaging process and enhances the user experience.

Other Industries

Two Shot Molding is not limited to the above-mentioned industries. It finds applications in countless other sectors, wherever the combination of materials and intricate designs is required.

Challenges and Considerations

While Two Shot Injection Molding offers numerous benefits, it also presents some challenges:

Part design and mold design for Two-shot mold 

Part design & mold design for 2K injection molding is totally different, because the molding machine is different to single colour molding machines, there are two shot molding machine has two nozzles in one machine, but there are three types of different Multi-Component Injection Molding machines (vertical nozzle, parallel nozzle, 45 degree nozzle), each type of machine needs different mold design, before design the 2K mold you must know the data of 2K molding machine in advance, to know how to design the two color mold you can download the Multi-Component Injection Mold Design Guild document below,

Two color molding

Two color molding

Material Selection

Choosing the right materials is critical. Compatibility and adhesion between materials are paramount to avoid defects or part failure, wrong material will make thing west.

Quality Control and Inspection

Quality control becomes more critical in Two Shot Molding. Ensuring that each part meets the required specifications demands rigorous testing and inspection processes.

Cost Factors

The initial investment in Two Shot Molding equipment can be higher than traditional molding machines. However, the long-term cost savings often outweigh the initial capital expenditure.

Case Studies and Examples

Let’s explore some real-world examples of case studies and examples that highlight the versatility and effectiveness of Two Shot Molding in various industries:

1. Automotive Shift Knobs:

  • Industry: Automotive
  • Application: Two Shot Molding is commonly used to manufacture shift knobs for automobiles. The process involves using a rigid thermoplastic for the core of the knob, providing structural integrity, and a soft thermoplastic elastomer (TPE) for the outer layer, ensuring a comfortable and non-slip grip.
  • Benefits: This approach combines durability with ergonomic design, creating shift knobs that are not only visually appealing but also comfortable and functional.

2. Medical Device Handles:

  • Industry: Medical
  • Application: Two Shot Molding is utilized for manufacturing handles for various medical instruments, such as surgical tools. The first shot involves a rigid material for the core structure, and the second shot consists of a different material to enhance the grip and ergonomics.
  • Benefits: The process results in handles that provide surgeons with a secure grip during delicate procedures while maintaining the necessary structural integrity.

3. Consumer Electronics Casings:

  • Industry: Consumer Electronics
  • Application: In the consumer electronics sector, Two Shot Molding is employed for creating smartphone and tablet casings. The first shot forms the core structure, while the second shot allows for the integration of different colors and textures, giving electronic devices a premium and customized appearance.
  • Benefits: Two Shot Molding enhances the visual appeal of electronic devices, making them stand out in a competitive market.

4. Multi-Color Packaging Seals:

  • Industry: Packaging
  • Application: Two Shot Molding is used to create packaging components with built-in seals, grips, or color variations. For example, closures for food containers that require both a sealing function and a different color for branding.
  • Benefits: This application streamlines the packaging process, reduces assembly steps, and enhances the user experience by providing secure seals and branding opportunities in a single manufacturing step.

5. Automotive Interior Trim:

  • Industry: Automotive
  • Application: Two Shot Molding is instrumental in producing automotive interior trim components, such as door handles and dashboard accents. The process allows for a combination of materials to achieve desired aesthetics and functionality.
  • Benefits: Interior trim pieces created through Two Shot Molding are not only visually appealing but also durable and functional, enhancing the overall quality of the vehicle interior.

These case studies demonstrate the adaptability of Two Shot Molding across diverse industries. By combining different materials in a single manufacturing process, it enables the creation of parts with enhanced aesthetics, improved functionality, and cost-efficient production. Whether it’s for automotive components, medical devices, consumer electronics, or packaging solutions, Two Shot Molding continues to play a pivotal role in modern manufacturing by offering design flexibility and process efficiency.

Future Trends and Developments in Two Shot Molding

Two Shot Molding is constantly evolving with emerging technologies and industry trends. Some key developments to watch for include:

Emerging Technologies

Advancements in injection molding machinery and materials are driving innovation in Two Shot Molding. New technologies offer even more precise control and efficiency.

Sustainability Initiatives

As the world places greater emphasis on sustainability, Two Shot Molding’s reduced waste and material efficiency make it an environmentally friendly choice.

Market Growth and Opportunities

The growth of Two Shot Molding is expected to continue, opening up new opportunities in various industries. Being prepared to harness these opportunities is essential for manufacturers.

Conclusion

Two Shot injection Molding has cemented its place as a game-changer in the world of plastic injection molding. Its ability to create intricate, multi-material parts with precision and cost-efficiency makes it a valuable technique for manufacturers across industries. As technology advances and environmental concerns grow, Two Shot Molding is poised to play an even more significant role in shaping the future of manufacturing. Whether it’s for enhancing product aesthetics or streamlining production processes, Two Shot Molding is a technique worth exploring and mastering in the world of modern manufacturing.

SINCERE TECH provides two-shot molding, and custom Plastic injection Molds & plastic injection molding service to all of the industries. Our state-of-the-art mold facilities and molding machines include a variety of processing and finishing equipment to manufacture plastic molds and parts from many types of industries, including complex specialty injection molds, such as:

  • two-shot injection molding
  • Unscrewing molds
  • Insert molding
  • Stack molds
  • Two shot mold (2K injection molding)
  • And many other types

2-K Mold, Multi-Component Injection Mold Design Guild Line

If you have a new project that wants to know the best manufacturing process and solutions? Send us an email to [email protected]. if you want to know more detail about our advantages, please go to our home page by https://www.plasticmold.net/.

insert molding

What Is Insert Molding

precision plastic injection molding

Precision Plastic Injection Molding

What is precision plastic injection molding?

Precision Plastic Injection Molding is tight tolerance requirement plastic injection molding parts. Normally tolerance on the plastic molding part is around 0.05-0.1mm, if the part tolerance requirement is about 0.01-0.03mm, that means this is precision plastic injection molding, to make high precision plastic injection molding parts, the first thing is making the precision injection mold, all of the mold components must have tolerance within 0.005-0.01mm.

This is min requirement for high precision plastic injection mold after mold is completed finished, then take mold trial to verify the dimension according to 2D drawing requirement, to trial the mold and make stable tolerance.

Precision plastic injection mold is number one key point to making high precision molding parts, but not limited to this, you still need use high precision injection molding machine to produce the part, by this two min requirement we can make sure that we can make precision molding parts continually, there are few issues that we make still need to know for the precision plastic injection molding.

Precision Plastic Injection Molding

Plastic precision Connector-overmolding

Question I:

The determination of the structure of the precision plastic mold is the key, and the overall structure is the embodiment of the final effect of the product: the determination of the overall structure of the mold, the determination of the gate system, the determination of the ejection system and the determination of the water transportation system, and others should be conducive to the post-processing orientation of the product.

Question II:

What about the feeding problem? First of all, we will choose a reasonable injection scheme according to the structure, weight, volume, and cost of the product, which can meet the requirements of customers as well as the requirements of quality.

Second, we will design in strict accordance with the injection design standards: the layout of the runner should be uniform, especially the size of the cross load surface of the main and sub runner, the shape and size of the gate.

Question III:

What about the ejection problem? Firstly, we will determine the ejection mode according to product orientation and structure. Secondly, we will evaluate the ejection balance and coexist with other systems, such as interference with water transportation and recycling marks, date clock, etc.

Question IV:

The design of the water channel system is based on four requirements (the cooling line should be as balanced as possible. The water cooling line shall not interfere with other mechanisms. The water channel equipment shall meet the customer’s standards and be easy to install. Each water channel line shall be displayed with identification numbers or marks (in and out).

 Question V:

How to ensure the manufacturing accuracy of the mold and the accuracy of the molding products to get precision injection molding, this mainly depends on the manufacturing accuracy of the mold cavity, the insert, and the mold core size. The accuracy of the mold cavity number or the accuracy of the parting line will directly affect the size of the product. Firstly, we need to make the manufacturing process plan and flow chart.

Each completed manufacturing process must be fully inspected and the data inspection list must be recorded in the datasheet. After the manufacturing is completed, the workpiece shall be processed and maintained.

The design of the parting line of plastic mold is also an important part. If the design is not reasonable, the part is not easy to demoulding or even damage the mold. Here are the design principles for the parting line of mold

It is convenient to eject out the plastic part and simplify the structure of the plastic mold. After the demoulding direction is selected, the position of the parting line should make the plastic part fall done without any interference, like sliders, etc.

For the plastic part with high coaxiality accuracy, the parting line should be selected at the position where two diameters can be placed on the lower mold or upper mold at the same time.

When the precision plastic injection molding along the height direction is required to be high, the half overflow cavity should be used. If the transverse flash is formed at the parting line, it is easy to ensure the height precision, while the non-overflow cavity is not easy to ensure.

When the radial dimension accuracy is high, the influence of flash thickness on the accuracy of the plastic part should be considered, as shown in the figure. If the vertical parting of plastic parts is easy to ensure, the horizontal profile is difficult to control due to the thickness of the flash, which affects the accuracy of plastic parts.

Ensure the appearance of the plastic part, it shall be easy to clean the flash and not easy to damage the appearance. The flash produced by the parting surface as shown in the figure shall be easy to clean and not easy to damage the appearance of the plastic part.

It is convenient for the manufacture of plastic mold and the processing of forming parts. The improved parting surface makes the processing concentricity of plastic mold low, easy to manufacture and the flash does not damage the appearance of plastic parts.

Ensure the strength of the formed parts, for example, when determining the parting surface, avoid the thin wall and sharp corner of the formed parts.

In addition to the design elements of general molds, the following points should also be considered in the design of precision injection molds:

  •  Adopt proper mold dimension tolerance;
  •  Prevent forming shrinkage error;
  •  Prevent deformation of injection part;
  •  Prevent the deformation of demoulding;
  •  The manufacturing error of the die/mold is minimized;
  •  Prevent the error of mould precision;
  •  Maintain mold accuracy.

Prevent the error of mold precision; classification of processing molds in plastic mold factory and requirements of various points for attention

There are many kinds of plastic injection molds, which can be roughly divided into ten categories. According to different requirements of a part material, physical and chemical properties, mechanical strength, dimensional accuracy, surface finish, service life, economy, etc, different types of injection mold are selected.

The plastic mould with high precision needs to be processed by a high precision CNC machine, and the material and molding process of the mould have strict requirements. Mould technology is also needed to design and analyze.

Some of the parts have special requirements during molding, so advanced technologies such as hot runner, gas-assisted injection molding, nitrogen cylinder, etc. are needed for plastic mold.

Plastic mold manufacturers shall have CNC machine tools, EDM machine tools, wire cutting machine tools, and CNC profiling milling equipment, high-precision grinder, high-precision three coordinate measuring instruments, computer design, and related software, etc.

In general, large metal stamping dies (such as automobile cover part die) should consider whether the machine tool has a blank holder mechanism, even edge lubricant, multi-position progressive, etc. In addition to the punching tonnage, the punching times, feeding device, machine tool and die protection device should be considered.

The plastic mold manufacturing capacity and process of the above are not possessed and mastered by every enterprise. When choosing a cooperative plastic mold manufacturer, we must know its processing ability, not only look at the hardware equipment, but also combine the management level, manufacturing experience, and technical force.

For the same set of mould, there is sometimes a big gap in the quotation of different mould manufacturers. You should not pay more than the value of the mold, but also should not be less than the cost of the mold. Plastic mold manufacturers, like you, want to make a reasonable profit in business, ordering a set of molds with a much lower price will be the beginning of trouble. You should start with your own requirements and measure them comprehensively.

If you have any requirement for precision injection molding manufacturing services, you are welcome to contact us, Sincere Tech is the leading customized precision plastic injection molding company in China. We offer precision injection molds and molding services to customers all over the world. Our team of experts specializes in providing customized precision injection molding services that meet the unique needs of our customers.

At Sincere Tech, we understand that every customer has unique requirements when it comes to high precision plastic injection molding. That is why we offer customized precision injection molding services, tailored to meet your specific needs. Our team of experienced professionals works closely with customers to understand their needs and provide the best solutions.

Our precision injection molds are designed and manufactured using state-of-the-art machinery and technology. We use high-quality materials to ensure the molds are durable and long-lasting, reducing the need for frequent replacements. Our precision injection molding machines are regularly maintained and calibrated to ensure consistent quality and fast turnaround times.

As a leading customized precision plastic injection molding supplier in China, we cater to a wide range of industries, including automotive, medical, and consumer products. We strive to provide the best quality at competitive prices. Our team takes pride in delivering excellent customer service and support, ensuring our customers are satisfied with our precision injection molding services.

At Sincere Tech, we believe in building long-lasting relationships with our customers based on trust, reliability, and quality. Our commitment to quality ensures that your products are manufactured with precision, accuracy, and consistency, helping you achieve your business goals.

If you’re looking for a reliable and experienced customized precision plastic injection molding company, contact Sincere Tech today. Our team is always ready to discuss your needs and provide you with the best solutions.

stainless steel CNC machining

Precision Component Production

What is Precision Component production

Precision component production refers to the manufacturing process of creating high-precision components or parts with extremely tight tolerances and exact specifications. These components are typically used in industries where precision is crucial, such as aerospace, medical devices, automotive, electronics, and other high-tech sectors.

Key characteristics of precision component production include:

  1. Tight Tolerances: The manufacturing process is designed to achieve very close tolerances, ensuring that the dimensions of the components meet exact specifications.
  2. Advanced Technologies: Precision component production often involves the use of advanced machining technologies such as CNC (Computer Numerical Control) machining, EDM (Electrical Discharge Machining), and other high-precision methods.
  3. Quality Control: Rigorous quality control measures are implemented throughout the production process to ensure that each component meets the required standards. This may involve the use of inspection tools, metrology equipment, and other quality assurance techniques.
  4. Materials: High-quality materials are used to manufacture precision components, and the choice of materials depends on the specific requirements of the application.
  5. Specialized Expertise: Skilled engineers and technicians with expertise in precision manufacturing are essential for ensuring the accuracy and quality of the components.
  6. Customization: Precision components are often tailor-made to suit the specific needs of a particular application. Customization may involve unique shapes, sizes, or materials.

The applications of precision components are diverse and can include critical parts for aircraft engines, medical implants, optical instruments, electronic devices, and other high-performance systems where accuracy and reliability are paramount. The precision component production industry plays a crucial role in supporting various technological advancements across different sectors.

Precision Component Production Machined Parts

Using state-of-the-art equipment and highly skilled personnel, we are professional precision component production company that produces small, tight tolerance components made from stainless steel, titanium, platinum, MP35N, various plastics and other materials in prototype through production volumes.

Our capabilities include CNC turning machines, CNC conventional lathes, wire, sinker, and small hole EDM, centerless grinding, CNC milling, precision deburring, laser welding, light assembly, special cleaning processes, automated passivation, die casting and injection molding service.

We can manufacture Precision Component Production parts from micro-miniature up to 1” maximum diameter capability. We excel on parts 3/16” diameter and smaller. Our tolerances range from +/-.0001 to +/-.001 and even +/- .00005 on certain features. Lastly, our surface finishes typically range from 8u” to 32u” (capable of 4u”) with tight cosmetic requirements.

Precision Component Production

Below are some of Precision Component Production machining process we use

Tube Drawing

Tube drawing is a manufacturing process used to reduce the diameter and thickness of tubes while increasing their length. It is a cold working process that involves pulling a tube through a die or series of dies to achieve the desired dimensions. This process is commonly used in the production of seamless tubes and pipes, and it allows for better control over the dimensions and surface finish of the final product.

Here is an overview of the tube drawing process:

  1. Material Selection: Tube drawing is applicable to various materials, including metals like steel, copper, aluminum, and alloys. The choice of material depends on the specific requirements of the application.
  2. Preparation: The process begins with a tube or pipe that is often pre-drawn to an initial size. The tube may undergo processes such as annealing to soften the material and make it more conducive to deformation.
  3. Drawing: The tube is pulled through a series of dies with progressively smaller diameters. Each die reduces the outer diameter while increasing the length of the tube. The process continues until the tube reaches the desired dimensions.
  4. Intermediate Annealing: In some cases, especially with materials that become work-hardened during drawing, intermediate annealing steps may be introduced to restore the material’s ductility and prevent cracking.
  5. Final Sizing: The final tube dimensions are achieved through a combination of drawing passes and the selection of appropriately sized dies.
  6. Surface Finish: Tube drawing can improve the surface finish of the tube, resulting in a smoother and more uniform appearance.

Tube drawing offers several advantages, including:

  • Dimensional Accuracy: Precise control over the tube’s dimensions, including outer diameter, inner diameter, and wall thickness.
  • Improved Mechanical Properties: The cold working process can enhance the mechanical properties of the material, such as strength and hardness.
  • Surface Finish: The process often results in a smoother surface finish compared to other manufacturing methods.
  • Cost-Efficiency: Tube drawing can be a cost-effective method for producing high-precision tubes in large quantities.

This process is widely used in industries such as automotive, aerospace, electronics, and construction, where precise tubing is essential for various applications.

Precious Metal and Clad Tubing

Precious metal and clad tubing involve the use of high-value materials, such as precious metals, in the manufacturing of tubes. These specialized tubes are designed for applications where the unique properties of precious metals or specific material combinations are required. Here are explanations for each:

  1. Precious Metal Tubing:
    • Materials: Precious metals such as gold, silver, platinum, and their alloys are used to manufacture tubing.
    • Applications: Precious metal tubing is often employed in industries where their unique properties are essential. For example, in electronics, precious metal tubes are used for electrical contacts due to their excellent conductivity and corrosion resistance. They may also be used in medical devices and jewelry.
    • Manufacturing Process: Precious metal tubing can be produced through various methods, including extrusion, drawing, or even specialized processes like electroforming.
    • Characteristics: Precious metal tubing is known for its high conductivity, corrosion resistance, and often for its aesthetic qualities.
  2. Clad Tubing:
    • Materials: Clad tubing involves combining two or more different materials to create a tube with specific properties. The materials may include metals, alloys, or even non-metallic materials.
    • Applications: Clad tubing is used when a combination of properties from different materials is required. For example, a clad tube might have an outer layer for corrosion resistance combined with an inner layer for structural strength.
    • Manufacturing Process: The manufacturing process for clad tubing can involve methods such as explosive bonding, roll bonding, or other bonding techniques. These processes ensure a strong metallurgical bond between the different layers.
    • Characteristics: Clad tubing allows for the customization of properties, combining the strengths of different materials. For instance, a tube can have a corrosion-resistant outer layer and a structurally robust inner layer.

Both precious metal and clad tubing are crucial in industries that demand specialized materials with specific properties. These industries include electronics, aerospace, medical devices, and others where precise material characteristics are essential for optimal performance. The manufacturing processes and material choices are tailored to meet the specific requirements of each application.

Deep Drawing

Deep drawing is a manufacturing process used to transform sheet metal into hollow, three-dimensional shapes with depth greater than their diameter. This process is commonly employed to produce various products, such as kitchen sinks, beverage cans, automotive parts, and appliance components. Deep drawing is characterized by the use of a punch and die to deform a sheet of metal into a desired shape.

Here is an overview of the deep drawing process:

  1. Material Selection: Deep drawing is typically performed on sheet metal, commonly aluminum, stainless steel, or other alloys. The choice of material depends on the specific properties required for the final product.
  2. Blanking: The process begins with a flat sheet metal blank, which is usually circular or rectangular. The blank is cut from a larger sheet in a process called blanking.
  3. Placing the Blank: The blank is placed over a die, which is a specially designed tool that defines the shape of the final product.
  4. Drawing: A punch is used to force the sheet metal into the die, creating a deep-drawn shape. The metal is stretched and formed to take on the contours of the die, resulting in a hollow part with a depth greater than its original diameter.
  5. Redrawing (if necessary): For more complex shapes or deeper parts, the drawn component may undergo additional drawing operations to achieve the desired final form.
  6. Trimming: Excess metal, known as the “flash,” is trimmed away from the deep-drawn part, leaving the final product.

The deep drawing process is suitable for producing a variety of shapes, from simple cylinders to more complex forms with irregular geometries. It offers several advantages, including:

  • High Production Speed: Deep drawing is a rapid and efficient process suitable for high-volume production.
  • Material Utilization: It minimizes material waste since the part is formed from a single blank.
  • Consistency: Deep drawing allows for the production of parts with consistent dimensions and shapes.
  • Cost-Effectiveness: The process is often cost-effective for large-scale manufacturing due to its efficiency and material utilization.

Deep drawing is widely used in industries such as automotive, aerospace, consumer goods, and appliance manufacturing, where the production of metal parts with specific shapes is essential.

Precious Metal and Clad Wire (Wire Drawing)

Wire drawing is a manufacturing process that involves reducing the diameter of a wire rod or a wire blank through pulling it through a series of dies. This process is used to produce wires with various diameters, improved dimensional accuracy, and a smoother surface finish. Precious metal wire drawing specifically refers to the application of this process to precious metals such as gold, silver, platinum, and their alloys.

Here is an overview of the precious metal wire drawing process:

  1. Material Selection:
    • Precious Metals: Gold, silver, platinum, and their alloys are common materials used in precious metal wire drawing. These metals are chosen for their unique properties, including conductivity, corrosion resistance, and sometimes for their aesthetic value.
  2. Wire Rod Preparation:
    • The process begins with a wire rod or a wire blank, usually obtained through processes like casting or extrusion. The initial wire may be annealed to improve its ductility and make it more amenable to the drawing process.
  3. Drawing Process:
    • The wire is passed through a series of dies with progressively smaller diameters. Each drawing pass reduces the wire diameter while increasing its length. This is achieved through the application of tensile forces.
  4. Intermediate Annealing (if necessary):
    • Precious metals can work-harden during the drawing process, and intermediate annealing steps may be introduced to soften the material and maintain its ductility. This helps prevent cracking and ensures the wire can be further drawn without issues.
  5. Final Sizing:
    • The process is repeated with different dies until the wire reaches the desired diameter. Each drawing pass imparts specific properties to the wire, including improved strength and a refined surface finish.
  6. Surface Finish and Cleaning:
    • The drawn wire may undergo additional processes to enhance its surface finish, and it may be cleaned to remove any residues.
  7. Spooling or Coiling:
    • The final drawn wire is typically spooled or coiled for ease of handling and transportation.

Precious metal wire drawing is crucial in various industries, including electronics, jewelry manufacturing, and medical devices, where the unique properties of precious metals are highly valued. The resulting wires can be used for applications such as electrical contacts, fine jewelry, and medical instruments. The process allows for precise control over the diameter, mechanical properties, and surface finish of the final wire.Plastic molding service

Fabricated Wire Products

SINCERE TECH specializes in every aspect of precision wire component fabrication and assembly. Beginning with a basic spool of wire, SINCERE TECH transforms many materials into a range of products, from straightened and cut tooling mandrels to sophisticated coronary guidewires that include complex core grind geometries and platinum coil spring tips.

Included in our wire expertise is the ability to engineer Nitinol wire products that capitalize on the unique super-elastic and shape memory properties of this material. We also manufacture both single and multi-filar coil assemblies for the most demanding applications, from cardiac rhythm management to catheter reinforcement. Whether you require a simple straight or complex wire component involving winding, coiling, grinding, welding and assembly, SINCERE TECH can deliver.

Extrusion

Precision Monomer and Composite Tubing Manufacture

SINCERE TECH manufactures precision monomer and composite tubing and catheter sub-systems to desired properties with the thinnest walls, tightest tolerances and smallest profiles for the best performance. We offer precision tubing that can be constructed from multi-layers of different materials, braid or coil reinforcement, and with variable flexibility along with the tubing. Additional capabilities include multilumen, tapered tubing, wire coating/insulation and coextrusion.

Materials include Polyimide, PTFE, FEP, Tecoflex, Tecothane, Memory Plastic, Nylon 11, Nylon 12, Pebax (several durometers), Nylon 6/6, and Polyethylene. Tubing sizes can range from .002″ ID to .200 with walls ranging from .0003″ to .010″. Braiding can consist of ultra-small flat or round stainless steel, Nitinol to non-metallic materials.

Virtual Tubing Model

SINCERE TECH offers tubing and catheter shaft modelling through the use of propriety software. The model will predict the optimum layer thickness and the combination of materials for the designer’s desired performance. The output of the model based upon material and dimensional inputs are crushability, flexibility, stretch, pushability, torquability, and kink radius. This allows the design to be developed with the shortest development time possible as design iterations can be made within the software instead of the manufacturing process.

Metal Injection Molding

SINCERE TECH’s proprietary precision metal injection molding process offers net shape metal parts to tight tolerances, which can be exceptionally cost-effective in volume in comparison to precision machined parts.

Injection and Insert Molding

multi-cavity moldsSINCERE TECH is an experienced ISO 13485-2003 registered provider of plastic mold and plastic injection molding for all of the industry using the latest methods. Our experience ranges from low volume single cavity molds to high volume multi-cavity molds and production. We have all of mold manufacturing and molding production equipment with the ability to produce various moulds, tooling, and parts. Our engineers can help with the development of your products in R&D all the way through the IQ, OQ and PQ process for production.

We are experienced in all thermoplastics, including polycarbonates, Ultems, polysulfones, pvc’s and elastomer materials. We do insert and overmolding and have extensive automation experience. Our valued added capabilities include engineering, metrology, testing, decorating, welding, sub-assembly, assembly, packaging and sterilization. Our press capability includes mirco-moulding, vertical molding, horizontal molding up to 300 tons with both highly versatile hydraulics and all of the electric molding machines.

Rapid Prototyping

SINCERE TECH is an experienced ISO 9000-2008 registered provider of plastic molding service for all of the industry using the latest methods. Our experience ranges from low volume single cavity molds to high volume multi-cavity molds and production. We have all of plastic mold manufacturing and molding production equipment with the ability to produce various mold and parts . Our engineers can help with the development of your products in R&D; all the way through the IQ, OQ and PQ process for production. We are experienced in all thermoplastics.

Final Assembly and Finished Product Packaging

SINCERE TECH offers true vertical integration in the areas of PTFE lubricious liners, braiding, coiling, extrusion, film cast materials, hydrophilic coating, and packaging to produce world-class catheter assemblies and packaged finished devices. The devices can utilize any one or more of different processes such as brainless-tip, integrated marker bands, and variable durometer polymers along the length of the shaft. Catheter assembly examples include stent delivery, rapid exchange, guide-catheters, and microcatheters for peripheral, cardiology, and neurology applications.

Are you ready to start your project now? Please send us an email, we will quote you the best price (30-35% lower price) for you.

Plastic molding manufacturing

Plastic Molding Technology

The History of Plastic Molding Technology

The history of plastic molding technology is a fascinating journey that spans several decades, marked by significant developments and innovations. Plastic molding refers to the process of shaping plastic materials into a desired form using a mold or die. Here’s a brief overview of the key milestones in the history of plastic molding technology:

  1. Early Developments (Late 19th Century):
    • The first synthetic plastic, Bakelite, was developed by Leo Baekeland in 1907. Bakelite was initially used for electrical insulators and later found applications in various industries.
    • Injection molding, the most widely used plastic molding process today, saw its initial concept in the late 19th century, but it wasn’t until the 1930s that it became a practical manufacturing method.
  2. World War II Era (1930s-1940s):
    • The demand for mass-produced, lightweight components during World War II accelerated the development and adoption of plastic molding technologies.
    • Injection molding gained prominence during this period due to its ability to produce complex and precise parts in large quantities.
  3. Post-World War II Advances (1950s-1960s):
    • The 1950s saw the commercialization of various plastic materials like polyethylene, polypropylene, and PVC, expanding the range of possibilities for plastic molding.
    • Blow molding, a process for creating hollow objects such as bottles, became popular during this era.
  4. Rotational Molding (1940s-1950s):
    • Rotational molding, also known as rotomolding, emerged in the 1940s and gained traction in the 1950s. This process involves rotating a hollow mold with powdered plastic inside to create a uniform coating on the interior.
  5. Thermoforming (1930s-1950s):
    • Thermoforming, a process where a plastic sheet is heated and molded into a specific shape, gained popularity in the 1930s and 1940s.
  6. Computer Numerical Control (CNC) Integration (1970s-1980s):
    • The integration of computer technology in plastic molding machines, known as CNC, enhanced precision and control in the molding process.
  7. Advancements in Materials and Techniques (1990s-Present):
    • Continuous advancements in plastic materials, additives, and molding techniques have allowed for greater versatility, durability, and efficiency in plastic molding processes.
    • 3D printing technologies have also influenced plastic molding, offering new possibilities for rapid prototyping and low-volume production.
  8. Sustainability and Innovation (Recent Years):
    • In recent years, there has been a growing emphasis on sustainable practices in plastic molding, with increased interest in biodegradable and recycled materials.
    • Advanced manufacturing technologies, such as Industry 4.0 concepts, are being integrated into plastic molding processes for improved efficiency and quality control.

The history of plastic molding technology is characterized by a continual evolution driven by technological advancements, material developments, and the changing needs of various industries. Today, plastic molding plays a crucial role in the production of a wide range of products across numerous sectors.

Plastic molding technology continues evolving with the market and with the advances in science. Plastic molding is the process used in producing plastic components for a variety of industries.

plastic molding technology

When plastic resin materials are heated the resin will flow, and can then be injected into a mold. A plastic mold consists of two halves referred to as the “A” side (cavity side) and the “B” side (core side). The “A” side is where the molten plastic enters the mold, and the “B” side contains the ejector system which removes the parts from the mold.

Advancements of plastic molding technology

Advancements in plastic molding technology have been significant, driven by innovations in materials, processes, and machinery. Some notable advancements include:

  1. High-Performance Materials:
    • The development of new and advanced plastic materials with enhanced properties, such as high strength, heat resistance, and durability, has expanded the application range of plastic molding.
  2. Biodegradable and Sustainable Plastics:
    • With increasing environmental concerns, there has been a focus on developing biodegradable and sustainable plastics. Manufacturers are exploring materials derived from renewable sources or those that can easily decompose, reducing the environmental impact of plastic products.
  3. Advanced Injection Molding Techniques:
    • Micro-injection molding allows for the production of extremely small and precise plastic components, opening up new possibilities in fields like electronics and medical devices.
    • Multi-material and multi-color injection molding enable the production of complex parts with different materials or colors in a single manufacturing cycle.
  4. Additive Manufacturing and 3D Printing:
    • The integration of 3D printing technologies into plastic molding processes has facilitated rapid prototyping, tooling development, and low-volume production. This allows for faster product iterations and reduced time-to-market.
  5. Industry 4.0 Integration:
    • The incorporation of Industry 4.0 principles, including smart sensors, data analytics, and connectivity, into plastic molding machines has improved automation, real-time monitoring, and overall efficiency in production processes.
  6. In-Mold Decorating and Labeling:
    • In-mold decorating (IMD) and in-mold labeling (IML) techniques allow for the integration of graphics, textures, and labels directly into the molded plastic parts during the manufacturing process. This enhances product aesthetics and eliminates the need for additional post-processing steps.
  7. Gas-Assisted Injection Molding:
    • Gas-assisted injection molding involves injecting a controlled volume of gas into the molten plastic to create hollow sections within the molded part. This technique is used to produce lightweight components with improved strength and reduced material usage.
  8. Foam Injection Molding:
    • Foam injection molding produces lightweight, rigid, and cost-effective parts by injecting gas or chemical blowing agents into the plastic melt. This process is particularly useful for automotive and packaging applications.
  9. Insert Molding and Overmolding:
    • Insert molding involves placing metal or plastic inserts into the mold before injection, creating a part with integrated components. Overmolding involves molding one material over another, providing benefits such as improved grip, aesthetics, and functionality.
  10. Liquid Silicone Rubber (LSR) Molding:
    • LSR molding is used for producing flexible and durable rubber-like parts. It is commonly used in medical devices, automotive components, and consumer goods.
  11. Robotic Automation:
    • The use of robotics in plastic molding processes has increased precision, speed, and efficiency. Robots are employed for tasks such as part handling, assembly, and quality control.

These advancements collectively contribute to the evolution of plastic molding technology, making it more versatile, efficient, and environmentally friendly. The ongoing focus on innovation continues to shape the future of plastic manufacturing processes.

 

Plastic Molding Includes Many Terms and Components

Plastic molds are required to have many components in order to make high-quality plastic parts. Below is some of the terminology used to describe the components and processes that are required when producing injection molded parts:

  • Sprue – this connects the nozzle of the injection molding machine to the main runner, or cavity
  • Runner – this component conveys the melted plastic from the sprue to the gate and into the part
  • Gates – these are the openings that allow the molten plastic to be injected into the cavities of the mold
  • Cold Runner mold – this design involves the plastic entering into the “sprue” and then traveling through the “runner” where it then enters the part cavities through the various “gates.”
  • Hot Runner mold – this design is an assembly of heated components used to inject molten pPlastic moldslastic into the cavities of the mold. Hot Runner mold usually makes mold more expensive to manufacture but allow savings by reducing plastic waste and reducing the cycle time.

When observing plastic molding products, you will often see a line running between different sides of the finished plastic part. Here are some descriptions of why parts have a specific appearance:

  • The Parting Line – this occurs anywhere there are any two pieces of mold that meet.

There are also several configurations of plastic molds. These configurations are described as

follows:

  • The Two Plate Mold – consists of one parting line where the mold splits into two halves.  The sprue, runners, gates, and cavities are all on the same side of the mold.
  • The Three Plate Mold – has a runner plate in between a moving half and a fixed half.  These molds will have two parting lines and are used because of their flexibility in gating locations.
  • An Unscrewing Mold – is what is used when there is a requirement for male or female threads on a plastic component
  • The Action Mold – these consist of a mechanical cam action incorporated in their design, when a hole, slot, undercut or thread is needed that is not perpendicular to the parting line.
  • The MUD Unit Mold– these are standard frameworks for toolsets (u-frame), which allow for custom-machined tooling inserts to be made for specific components.

Large Plastic Molding Runs Cost Less 

Plastic injection molding offers many industries a huge number of benefits.  In large runs, molding is much cheaper than when machining the parts individually. The over-all manufacturing speed is much faster with this approach as well. This is one of the many reasons there are so many different types of injection molding processes. Some of these include:

Cold runner mold

Insert Molding – This is the process of putting a metal insert into a mold and then molding plastic around the insert.  Since multiple parts are manufactured together – this eliminates the need for a secondary assembly operation.

OverMolding – This is the process of over-molding, and the production of injection molded parts that seamlessly combines a rigid plastic with a rubber-like elastomer.

Family Molding – This is a process that utilizes a mold that contains various shapes of cavities to mold all the plastic components for one completed part.  Family molds are used when the different plastic components are made from the same material.

Injection Molding CleanRoom – This is the process used primarily for medical components. It is the injection molding process that is performed in a cleanroom environment in order to protect the parts from any contaminants.

When considering having plastic parts custom designed and molded – SINCERE TECH is the ideal partner for your plastic component or device.

SINCERE TECH is a China mold maker, which is  your single-source solution for your device by providing mold building, design, and engineering, injection molding as well as injection molding cleanroom and any secondary operations that may be required to complete your project. contact us now to know more information