2 shot injection moulding can integrate multiple functions into one plastic part, such as soft-sensitive surfaces, ergonomic design, two-colour appearance, brand identity, feature improvement, noise reduction, shock absorption, water resistance and impact protection, saving design space and reducing the number of components, etc.

The impact of Sussex Injection Molding extends far beyond the confines of its facilities, reverberating throughout the plastic manufacturing industry. Through its relentless pursuit of innovation and excellence, the company has not only elevated industry standards but also catalyzed advancements in material science, process optimization, and product development. Its contributions have not only reshaped the landscape of plastic manufacturing but also empowered businesses to thrive in an increasingly competitive market.

Because of the different chemical properties of different plastics, their compatibility will directly affect the bonding strength and bonding effect of the bonding surface, not all plastics have good compatibility with each other.

In this article, the first injected material is referred to as the base material and the second injected material is referred to as the overlay material.

1) Used in power switches, mobile phone keys, car switches, etc. to meet the requirements of partial light guidance or light transmission.

The strength of the bond between the base material and the cover material depends on the compatibility between the materials, the process temperature, the bonding surface, the moulding sequence and the design of the internal bonding surface mechanical interlocking structure.

Injection molding stands as a cornerstone in the realm of plastic manufacturing, with Sussex Injection Molding emerging as a beacon of innovation and excellence within this domain. Founded in 1977, Sussex Injection Molding has carved a niche for itself by consistently delivering high-quality, precision-engineered plastic components across various industries. This article endeavors to explore the intricate workings of Sussex Injection Molding, shedding light on its processes, capabilities, and contributions to the field of plastic manufacturing.

PTS Industrial Ltd is Specializing in precision manufacturing and injection molding parts since 2002. We supply CNC machining (milling&turning) parts and injection molding parts for various industries to customers worldwide.

Today I’m going to show you an article to let you understand 2k injection molding in 2022!(2k Injection Molding Factory/Expert/Supplier based on China.)

Plastics are different, their chemical properties are different, and their compatibility will directly affect the bonding strength and bonding effect of2 K injection moulding/double injection molding.

2)The difference between the melting temperature of the base material and the covering material does not exceed 30-60°. The melting temperatures of common plastics are shown in the following chart.

Therefore, when designing products for two-colour injection moulding，The first and most important thing is to choose the most suitable substrate material and covering material。

The different TPE models from RTP, as pictured, differ considerably in their compatibility with plastics, even though they all belong to the TPE range (X indicates good compatibility).

After the 1st injection, if the surface of the part fits directly into another fixed mould, it should be ensured that the plane has a sufficiently large release slope to avoid scratching when the mould is closed.

A toothbrush is a product that combines hard and soft plastics. A hard plastic is used for the main part of the toothbrush to provide sufficient strength; a soft plastic is used for the part that comes into contact with the hand to ensure a tactile feel; at the same time two-colour injection moulding provides the toothbrush with a colourful appearance.

In an era where environmental sustainability is paramount, Sussex Injection Molding stands at the forefront of environmentally conscious manufacturing practices. The company is dedicated to minimizing its ecological footprint by implementing eco-friendly materials, optimizing energy usage, and reducing waste generation. By embracing sustainable solutions, Sussex Injection Molding not only fulfills its corporate responsibility but also sets a precedent for eco-friendly manufacturing practices.

The Draft Angle is important for two-colour injection moulding because it determines which mould the part is attached to during the rotation process.

2) The plastic is in a molten state throughout the entire process of two-colour injection moulding, with no cooling shrinkage, which means that there is the opportunity to form a strong chemical link between the base material and the overlay material, with high strength and reduced risk of burrs occurring.

3) Compared to insert/overmold injection moulding, 2k injection moulding does not require the insertion of inserts, resulting in shorter and more efficient moulding cycles, as well as higher quality.

Sussex Injection Molding traces its roots back to humble beginnings, founded with a vision to revolutionize plastic manufacturing. Established in Sussex, Wisconsin, the company embarked on a journey fueled by a commitment to quality, innovation, and customer satisfaction. Over the years, it has evolved from a modest operation into a state-of-the-art facility equipped with cutting-edge technology and a team of skilled professionals dedicated to pushing the boundaries of possibility.

2k injection moulding is the simultaneous injection of two plastics at once in a dedicated two-colour injection moulding machine.

2k injection molding（2shot injection molding or double shot injection molding）is a manufacturing process used when referring to molding two materials/colors into one plastic part. This plastic molding technology blends two materials or two different colours materials into one ending plastic part by using 2k injection molding machine.

Looking ahead, Sussex Injection Molding is poised to continue its legacy of innovation and leadership in the plastic manufacturing industry. With a steadfast commitment to technological advancement, customer satisfaction, and environmental sustainability, the company remains primed to tackle the challenges and opportunities that lie on the horizon. By staying true to its core values and embracing emerging trends, Sussex Injection Molding is well-positioned to shape the future of plastic manufacturing for generations to come.

2k injection moulding is a type of injection moulding, so DFM design guidelines for injection moulding, such as uniform wall thickness, avoidance of sharp corners and even transitions, must also be observed for 2k injection moulding.

One of the hallmarks of Sussex Injection Molding is its ability to provide custom solutions tailored to meet the unique needs of each client. Whether it's prototyping, design optimization, or full-scale production, the company works closely with clients to develop bespoke solutions that align with their specifications and objectives. This personalized approach not only fosters strong partnerships but also ensures the delivery of superior-quality products that exceed expectations.

3）Products that require a multicoloured appearance, such as keyboards, the use of two-colour injection moulding makes them beautiful without the risk of rubbing off during use.

When the internal bonding surface is too small, the roughness can be increased by nibbling on the bonding surface on the one hand, and mechanical interlocking structures can be designed on the other.

In the plastics family, only ABS and polysulfone (PSU) surfaces can be plated. If a partial area or a single side of the product requires plating, the plated area should be injected with ABS and the area that does not require plating should be injected with other materials such as PC.

After the second opening of the mould, the moving mould, which has already been injected twice, will ejected the plastic 2k part.

The weight difference between the base material and the cover material should not be too big different, otherwise it will affect the moulding cycle and injection pressure etc.

The chart above can be used as a general selection guide only. It is always best to contact your plastics supplier for a more professional opinion when selecting a specific material type. You can contact us too! info@ptsindu.com

The first injection of the base material and the second injection of the cover material are injected out simultaneously, requiring two injection nozzles on the injection machine, each injecting a different colour or a different base material and cover material.

At the heart of Sussex Injection Molding lies a commitment to leveraging advanced technology to streamline processes and enhance efficiency. The company boasts a comprehensive suite of injection molding machines, ranging from small-tonnage to large-tonnage presses, capable of accommodating a diverse range of production requirements. Additionally, its utilization of automated robotic systems ensures precision and consistency in every molded component, minimizing defects and maximizing productivity.

The design of the Cosmetic mating surface at the first and second injection is very challenging and must provide sufficient bonding strength, otherwise flying edges, burrs, rolled edges and flaking can easily occur, especially in 2k injection moulding of hard and soft plastics. Common Cosmetic mating surface designs include stepped and fluted.

Quality lies at the core of everything Sussex Injection Molding does, underpinned by rigorous quality assurance processes and stringent adherence to industry standards. From material selection to final inspection, every step of the manufacturing process is meticulously monitored and controlled to uphold the highest standards of quality and consistency. This unwavering commitment to excellence has earned the trust and loyalty of clients across a myriad of industries.

After the first injection of the base material, the mould is opened and then rotated by 180° using the rotatable structure of the injection machine, then closed the mold and start second shot inejction by using a different colour of material or a different material (covering material) than the first injection.

2）Application to hand-held products such as walkie-talkie housings, toothbrush handles, power tool handles, spanners and thermoses to improve feel.

The two plastics are injected on the same injection moulding machine and moulded twice, but the product only comes out once. Therefore, two-colour injection moulding is usually done by one set of moulds and requires a special two-colour injection moulding machine.

(1) Insert/over moulding is done using a common injection moulding machine, where the product is taken out from one mould and then put into another mould for a second injection moulding.

In conclusion, Sussex Injection Molding stands as a testament to the transformative power of innovation and dedication. From its humble beginnings to its status as a trailblazer in the industry, the company exemplifies excellence in every facet of its operations. As it continues to push the boundaries of possibility and redefine the standards of plastic manufacturing, Sussex Injection Molding serves as an inspiration to aspiring entrepreneurs, industry professionals, and environmental advocates alike.

On the first injection, the part should be attached to the moving mould; on the second injection, the part should be attached to the ejector side of the mould.