Multi-component injection moulding: powerful and versatile
Versatile innovations for your products
Multi-component injection molding combines the best properties of Plastic, elastomer and Metal in a single component and thus enables a large number of application examples.
Thanks to proven manufacturing processes, we can combine several components into 2K and even 3K molded parts. We have many years of experience both in plastic injection molding and in the production of technically demanding silicone components. Even projects with 3 connected materials are no problem. For example, metal elements can be overmoulded with plastic and at the same time with a elastomer seal be equipped.
We accompany you throughout the entire project and organize the tool and sample production as well as the production and optionally also the assembly of the serial parts.
In order to create an offer, we need either an initial technical drawing or an existing sample. However, if you do not yet have such a template, our product designers can also design and develop a suitable molded part for you.
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NEW: Molding of magnets with silicone
Advantage of multi-component injection molding
Material combination
With multi-component injection molding, different materials such as plastics, elastomers and metals can be combined in one component. This opens up a wide range of possibilities for optimizing material properties and enables the creation of innovative products with improved functions and performance.
design diversity
The technology makes it possible to implement complex geometries and designs that would not be possible with conventional injection molding processes. With multi-component injection molding, for example, soft seals can be integrated into complex plastic housings or metal inserts can be integrated into plastic parts.
weight loss
The use of lightweight materials such as plastics in combination with metals or other composites can reduce the weight of components, which is of great importance in various industries, especially in the automotive and aerospace industries. Combining rubber with a lightweight material like aluminum creates a lightweight yet flexible component that can be beneficial in a variety of applications.
cost
Although multi-component injection molding can initially involve higher investments in molds and machines, the overall costs can be reduced by integrating several functions into one part. This results in optimized assembly and reduced material and labor costs.
Improved functionality
The combination of different materials enables the integration of specific properties in one component. For example, hard components can contribute to stability, while soft components provide sealing functions or cushioning properties. The use of elastomers can reduce vibration and noise transmission, which makes 2K rubber-metal parts, for example, attractive in many industries, including automotive and mechanical engineering.
wear resistance
Rubber can provide an extra layer of protection to protect the metal parts from wear and tear, extending component life.
Efficient Manufacturing
With multi-component injection molding, complex components can be manufactured in a single manufacturing step, which simplifies the production process and shortens production times.
Environmentally friendly
The weight reduction and the possibility of combining different materials in one component can help to reduce material consumption and thus contribute to sustainability and resource conservation.
Insert & outsert technology
insert technique
One of the key processes in multi-component injection molding is insert technology, in which metal or plastic parts are firmly connected to one another. This is done by inserting threaded bushings, screws, plug contacts or other inserts into the injection mold and connecting them to the thermoplastic substrate.
outsert technique
Outsert technology makes it possible to spray plastic elements onto a prefabricated metal carrier. Here, the metal insert, also called “outsert”, is placed in the injection mold and the thermoplastic material is then injected around the metal part to create a strong connection.
The main difference to the classic insert technique is that the insert in the outsert technique has a larger volume than the plastic that is overmolded. This creates a strong and stable connection between the metal and the plastic, which combines the advantages of both materials.
Metal components in an elastomer composite
In addition, we also offer machined metal components in elastomer composites. A milled metal component, for example made of stainless steel, aluminum-zinc or copper alloys, is bonded to the elastomer with a material bond. Common elastomer materials such as silicone, EPDM, NBR and others enable a wide range of possible applications and specific damping characteristics.
The combination of different color and hardness variations of the soft component opens up numerous variants that can be precisely tailored to the requirements of customer-specific applications. The milled metal base enables classic shaft-hub connections or screw threads for connection to peripheral elements. This opens up applications in various sectors, such as mechanical and plant engineering, the automotive industry for shock absorbers or in the industry for transport rollers.
overmoulding of magnets
The integration of silicone coating and magnets creates innovative and versatile products. A striking example of this is our recently produced silicone bracelet with integrated magnets.
The positioned magnets are evenly spaced in the bracelet, making it easy to put on and take off the tracking watch for almost all wrist widths. This targeted placement ensures comfort and adaptability in everyday use.
The silicone coating acts as a protective shield for the magnets, protecting them from moisture, dust, chemical influences and mechanical stress. This robust protection mechanism ensures that the magnets maintain their optimal performance and durability. In addition, the silicone can be easily cleaned and disinfected, which is a great advantage, especially in times of increased hygiene requirements.
Also worth emphasizing is the critical role of temperature control in the overmolding process. Accurately controlling temperatures ensures that the silicone precisely cures and takes on the desired properties. This is essential as excessive heat can affect magnetism, while too low temperatures could result in incomplete curing.
With our many years of expertise in the field of silicone technology, we are very familiar with this technology and look forward to realizing innovative products with overmoulded magnets for you
Application examples for multi-component injection molding
Handles with cushioning
For tools, hand tools or bicycles, hand grips can be made that have a hard component for stability and a soft component for comfortable cushioning.
automotive sealing systems
In the automotive industry, multi-component injection molded parts are used for seals to ensure optimal sealing against moisture, dirt and noise. They are also used in bearings, steering components and shock absorbers to reduce vibration and improve driving comfort.
Medical equipment
An example is a medical device where the hard plastic component provides a robust structure, while the soft silicone component improves skin tolerance and patient comfort.
Electronic enclosures
Here the different materials can contribute to achieve a robust structure of the housing with integrated seals, electrical conductivity or protective functions.
Domestic appliances
For example, in a coffee maker, multi-component construction can improve durability and insulation.
lightweight constructions
In the aerospace industry, multi-component injection molded parts can help reduce weight while increasing strength and safety.
sports and leisure items
Ski and snowboard grips with cushioning or ergonomic handlebar grips for bicycles are just a few examples of the use of multi-component injection molding in this area.
Electronic components
Multi-component injection molded parts are also used in the electronics industry, for example in housings for smartphones or tablets, to achieve a combination of durability and aesthetic design.
