Ireland — 2k moulding is one of the most innovative processes in use in plastics manufacturing today. Although the concept has been around for many decades, as with all tech processes, there have been a lot of technological advances in the use of 2k moulding in recent times. With a wide set of applications, it has many practical uses.

2k moulding — sometimes known as double injection or two shot moulding — is a very innovative way to produce complicated moulded parts from two different materials. It’s a highly meticulous, specialised and automated manufacturing process which controls the injection of multiple materials. It is specialised because it involves the combination of hard and soft thermoplastics or thermoplastic (TP) and thermoplastic elastomer (TPE). It’s applicable to a broad range of products; think medical devices, keys on a computer keyboard and even all the specific parts that go into a car’s headlights.

There are many other potential uses for it too. For example, it can be used to improve the grip on product handles — for items like power drills, toothbrush’s, walkie talkie’s etc. Plastics are integrated into the product grip and this can be done through the use of 2k moulding.

Simply put, the plastic moulding technology blends two materials or two different colour materials into one ending plastic part by using a specific 2k injection moulding machine. This machine has the power to take two totally different polymers and transform them into a single, final product.

Combining Injection Moulding and Extrusion Technology

A chemical bonding process is required so that the two or more materials can be combined into one component. The strategic choice of materials are a fundamental factor for the project’s success or not when using 2k injection moulding. Also, throughout this process, it’s vital to use the appropriate classification of cleanroom, given the type of product you are creating.

2k moulding is performed on one machine which is programmed to perform two injections in one cycle. In the first cycle, a nozzle injects plastic into a mould. The mould is then automatically rotated and a different type of plastic is injected into the mould from a second nozzle. The 2k moulding machine can create a highly effective end result from very different polymers.

A 2k moulding machine needs to be kitted with multiple injection screws; either a rotating tool, a transfer tool and/or a moving core tool; and any other required supporting equipment.

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A common question. Let’s first define overmoulding. Overmoulding is also a type of injection moulding process that allows for the combination of two or more different materials into a single product. This usually includes a rigid, plastic-base component overlaid with a pliable, thin rubber-like thermoplastic elastomer (TPE) exterior layer or other materials using either a one shot (insert moulding) or two shot (2k) technique. The main differences between overmoulding and 2k moulding can be summarised as follows: Overmoulding can be both a single shot (insert moulding) or two-shot. 2k moulding is just a 2 shot process. 2k tends to be a lot bigger than overmoulding and is used for larger operations.

In the overmoulding process, the material used must be cold to be removed. However with 2k moulding, the polymer is typically still flexible and hot — therefore it allows for more greater functionality. 2k moulding allows for large number of materials that can act as the moulding substance or equally be moulded on. With overmoulding, you are more restricted with the usable materials.

There are many advantages to 2k moulding including:

These are the main benefits associated with 2k moulding. While the counter argument and potential drawback is that the mould for 2k moulding and running the 2k moulding machine is more expensive… where high volume is needed, the overall cost and time can be significantly lower, thanks to a greater reduction in overall assembly and labour costs.

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