Twin Shot Moulding

Prepared by Shrikanth Siddayya

1

What is it?
Producing two colour or two component injected moulded parts from two different thermoplastic materials in one process, quickly and efficiently.
Two-shot plastic injection moulding, co-injection, two-colour and multi-component moulding are all variations of an advanced moulding technology
Combining hard plastics with soft materials
Two step process performed during a single press machine cycle
Consolidates two or more components thus eliminating additional assembly costs
The technology of injection moulding continues to become increasingly sophisticated. Up-to-date fabrication technology allows processors to produce
injection moulded parts from two different thermoplastic materials.
By combining these different materials with the ever-improving moulding technology, complex functional parts can now be produced economically and
efficiently in massive quantities.
The materials may differ in polymer type and/or hardness, and can be fabricated from moulding techniques such as dual injection moulding, two-shot
moulding, two colour moulding, two component moulding and/or multi-shot moulding.
Whatever its designation, a sandwich configuration has been made in which two or more polymers are laminated to take advantage of the properties each
contributes to the structure.
The thermoplastic parts from these mouldings offer excellent performance characteristics and reduced cost.

How does it work?

1. Two shot machine with two independent injection units
2. Moulding one part using two different materials or colours
3. Two cavity mould (one + one)
4. First material injected into first cavity, mould opens and rotates to second cavity position, mould closes and second material is injected. After sufficient
part cooling, the mould is opened and the part is ejected.
Critical factors:
material(s) melt temperature
mould wall temperature
injection speed
delay time between injections
component part temperature
The two-shot plastic injection moulding process requires a machine with two independent injection units, each of which shoots different material. The first
material is injected through a primary runner system, as in a normal injection moulding cycle.
During the injection, the mould volume to be occupied by the second material is shut off from the primary runner system. The mould is then opened and the
core plate rotated 180 degrees.
The mould is again closed and the secondary runner system is connected to the volume to be filled. After sufficient part cooling, the mould is opened and the
part is ejected.
The two-shot process can also be accomplished with an indexing system (a round table rotating around a horizontal axis) with a primary and secondary
station. While the first injection is accomplished at station 1, the second injection is accomplished at station 2.
Each injection station is run by an independent injection unit. This allows injection speeds and pressures to be controlled for each material being utilized.

What are the Benefits?

1. Lower part cost: savings in production, handling, assembly and inventory
2. Simplifies the production process with higher quality fabrication
3. Eliminate secondary operations
4. Improves integrity of the product
5. Enhances product features and appeal: tactile, ergonomic, cosmetic
6. New design possibilities
7. Packaging applications where a secondary colour is desired to give products a unique appearance
8. Added features to improve part functionally: multiple colours, soft touch surfaces, gaskets and seals
The real payoff of two-shot plastic injection moulding of thermoplastic materials is an economic one. Parts of two different materials can be fabricated with
the speed, efficiency and economy of thermoplastic processing.
This eliminates the labour-intensive secondary operations used for so many years and replaces them with high-speed automated operations, to yield a more
consistent, higher quality fabricated part at a significantly lower cost.

Twin Shot Moulding is ideal for

1. Soft touch handles, grips and other components
2. Multi-colour buttons, switches and knobs
3. Movable segments or components
4. Water shield and protection
5. Caps and enclosures
6. Back-lit buttons, dials and other instrumentation products
7. Drop protection
8. Vibration and noise dampening and isolation