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December 12, 20131
Challenges in multi-
component injection molding
Martin VarchPhilips Austria GmbH
December 12, 2013
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December 12, 20132
Challenges in multi-component injection molding
Content
• multicomponent injection molding
• Factors of influence
• Examples
– Arielle Housing
– Waterfall
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Injection molding
Screw rotates and
fills the barrel
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December 12, 20136
Injection molding
Screw rotates and
fills the barrel
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Barrel is filled and ready for injection
Injection molding
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December 12, 20138
V
Injection molding
injection
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V
Injection molding
injection
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P
Injection molding
holding pressure
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Injection molding
Cooling and shrinking
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Injection molding
Cooling and dosing
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December 12, 201316
Injection molding
Cooling and dosing
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December 12, 201319
Injection molding
Mold opens and throws the part out of the cavity
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December 12, 201320
Injection molding
ejecting
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December 12, 201321
Injection molding
ejecting
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December 12, 201322
Injection molding
ejecting
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December 12, 201323
Injection molding
ejecting
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December 12, 201324
Injection molding
Mold closes and process start again
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Injection molding
Mold closes and process start again
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December 12, 201330
Arielle Housing
Examples
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December 12, 201331
Arielle Housing
Requirements
– Part for water tight epilator
– High gloss surface
– Switching function included
– No injection point(s) visible
– No Parting Lines visible
– Molded 3D deep-view effects
– Hidden LED
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December 12, 201332
Arielle Housing
Challenges : Technology choice
1. 2 x 2 k + Pins
2. 4 k + Pins
3. …..
Step 1: 3 k Panel
Step 2: 1 k Housing + Pins
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December 12, 201333
Arielle Panel
Challenges: Out-washing effects of design-layer
1. DOE with 32 materials to get best
performance
1st Layer PC
2nd Layer MABS
Build a kind of jump for2nd component
1st component
2nd component
2. Injection situation
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December 12, 201335
Arielle Housing
Challenges: Seal the 3D contour of Panel
die (ejector side side)
Pin sliderslider
die (nozzle side)
HousingPanel
core
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December 12, 201336
Waterfall
Main Cover Overmold
Examples
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December 12, 201337
Waterfall Main Cover Overmold
Requirements
• Water tight
• Deep view effect
• Switching function included
• No parting lines visible
• Hidden LED
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December 12, 201338
Waterfall Main Cover Overmold
challenges
3rd Component without
additional injection unit
Main Cover
switch
Main Cover
Additional 2-component
insert part
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December 12, 201339
Waterfall Main Cover OvermoldChallenges: out washing effects
no other possibilities to inject
(thick wall <7mm high gloss)
Injection point
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Thank you
