Multi-component injection molding for multifunctional injection molded parts
Multi-component injection molding combines the best properties of Plastic, Elastomer and Metal in a single component. This results in multifunctional components that combine mechanical strength, soft sealing zones, transparent elements or tactile surfaces in a targeted manner.
Thanks to proven manufacturing processes, we process multiple components into 2K and 3K molded parts. With our many years of experience in plastic injection molding and the production of technically sophisticated silicone components, we can implement even complex projects with precision. For example, metal elements can be overmolded with plastic and simultaneously provided with an elastomer seal.
Multi-component injection molding not only reduces assembly steps and lowers costs, but also significantly increases design freedom and technical precision. The homogeneous bonding of the materials also ensures lasting stability and tightness – even under demanding conditions.
We accompany you through the entire project process – from tool and sample production through to production and optional assembly of the series parts.
Design guide
Plastic molded parts
References of multi-component injection molded parts
Here you will find selected reference projects that illustrate the versatility of our manufacturing solutions in multi-component injection molding. Our projects demonstrate how different materials can be combined in a single component to achieve maximum functionality and optimal performance.
Application examples for multi-component injection molded parts
Multi-component injection molding allows for the combination of different materials in a single component. Here are some examples from various industries:
- Electronic enclosures
Electronic devices benefit from robust housings reinforced by multi-component technology. Integrated seals provide additional protection, while special materials ensure electrical conductivity or shock resistance.
In addition, we also develop and manufacture tailor-made plastic molded parts with integrated magnetic connectors. This involves powerful Spring contact pins and magnets are integrated directly into the housing design – for a compact, reliable and intuitive connection solution. - Handles with cushioning
Ergonomic handles are manufactured for tools, handheld devices or bicycles. While the hard component ensures stability, the soft component offers pleasant cushioning. This improves grip, comfort and vibration absorption. - automotive sealing systems
In the automotive industry, multi-component injection-molded parts are used in seals, bearings, steering components, and shock absorbers. They offer optimal protection against moisture, dirt, and noise. At the same time, they reduce vibrations and increase driving comfort. - Medical equipment
In medical devices, the hard plastic component ensures a stable structure, while the soft silicone component improves skin compatibility. This increases wearing comfort and enables safe use. - Domestic appliances
Multi-component components increase the longevity and safety of household appliances. In coffee machines, for example, special material combinations improve durability and ensure effective insulation. - lightweight constructions
In the aerospace industry, multi-component injection molding helps reduce weight without compromising strength. This creates lightweight but durable components that can withstand high loads.
technology in multi-component injection molding
Insert technology – overmolded metal inserts
Insert technology enables the form-fitting and force-fitting integration of metallic inserts into injection-molded plastic components. Elements such as Threaded inserts, contact pins or fastening elements specifically inserted into the tool and precisely in the injection process overmolded with the carrier materialThe result is a highly stable hybrid solution that combines mechanical strength with the functional properties of the plastic – without any downstream assembly steps.
Outsert technique – plastic on metal
Outsert technology is a special process in which plastic structures are applied directly to prefabricated metal supports. The metal component is first inserted into the mold, followed by targeted overmolding with thermoplastic material. This creates a high-strength bond that combines the mechanical stability of metal with the functionality and design freedom of plastic.
In contrast to the insert technique the metal content predominates in outsert components – ideal for designs where structural strength and precise dimensional accuracy are paramount. This method has proven particularly effective in areas with high demands on robustness and precision – such as the automotive sector, mechanical engineering, or medical technology.
Metal components in elastomer composites – flexibility and damping
In addition to the combination of plastic and metal, we also offer the integration of machined metal components with elastomers Here, a milled Metal component bonded to elastomerThis technology enables highly functional solutions for applications with special requirements for damping, flexibility and durability.
Elastomer materials such as silicone, EPDM or NBR offer excellent damping properties and high chemical resistance. By combining different color and hardness variations, components can be tailored precisely to customer-specific requirements. This creates high-precision components that are used, for example, as shock absorbers in the automotive industry, sealing elements in mechanical engineering or transport rollers in industrial plants.
Perfect material combinations for Multi-component injection moldingcastings
The multi-component injection molding offers a variety of possibilities to create functional and visually appealing products. This process allows combine hard and soft plastics in one component or produce multi-colored products efficiently. To ensure that the desired material properties are achieved, the correct selection of materials is crucial.
We've compiled a material overview that shows which combinations combine particularly well and which are less suitable. This overview helps developers and designers select the optimal material pairing for their individual requirements. The right material combination contributes significantly to the quality, durability, and performance of the final product.
This You can also find the table in our Design Guide Plastic Moulded Parts >>
Advantages of multi-component injection molding
material combination for optimal properties
Multi-component injection molding allows for the targeted joining of thermoplastics, elastomers, and metals. By combining different Shore hardnesses, flexible yet stable structures can be created. Furthermore, it is possible to coat metal inserts with a protective layer of TPE to make components vibration-damping. In the electronics industry, the use of conductive plastics contributes to the shielding of electromagnetic radiation. A typical example is a two-component housing with an integrated seal, which provides reliable IP68 protection while simultaneously simplifying assembly.
Design diversity and precise geometries
Multi-component injection molding allows for the creation of complex shapes that would be impossible to produce using conventional manufacturing methods. Intricate structures with wall thicknesses starting at 0,5 mm enable precise design, while the seamless joining of different materials ensures greater stability.
Weight reduction for lightweight constructions
Weight reduction plays a crucial role in the automotive and aerospace industries. The use of fiber-reinforced plastics or hybrid components made of aluminum and TPE allows for the production of lighter yet robust components. The targeted selection of materials enables weight reductions of up to 30% without compromising mechanical strength. This reduced weight not only improves energy efficiency but also reduces material usage, thereby lowering production costs.
Cost efficiency through functional integration
The ability to combine multiple functions in a single component makes multi-component injection molding particularly economical. While initial investments in tooling and machinery may be higher, the reduced assembly effort leads to long-term cost savings. Fewer assembly steps and a lower scrap rate result in optimized production with reduced material consumption. This lowers both manufacturing costs and resource requirements. One example is a rubber-metal damping element manufactured using 2K injection molding, eliminating the need for separate bonding. Furthermore, production time can be reduced by up to 40%, enabling companies to achieve significant efficiency gains and shorter lead times.
Improved functionality and durability
By strategically combining hard and soft materials, components can be optimized for extreme operating conditions. TPU overmolding can protect sensitive metal components from corrosion and abrasion, while vibration-damping elastomers reduce vibrations. An overmolded metal bolt with a special protective coating is one example of the increased durability of these components. Particularly in the machinery and automotive industries, such solutions help to extend the service life of components and minimize maintenance.
Wear resistance and longer service life
Components subjected to high mechanical stresses benefit from additional protective layers, as these significantly increase surface durability and service life. The use of abrasion-resistant elastomers or PTFE-coated materials effectively reduces wear, thereby significantly extending the service life. Furthermore, housing edges with integrated TPU reinforcements provide improved impact resistance and simultaneously increase resistance to mechanical stress. Another example is an ergonomic handle system for tools that combines a hard plastic base with a non-slip rubber overmolding – resulting in stable, secure, and comfortable handling even during intensive use.
Efficient manufacturing with shorter production times
A major advantage of multi-component injection molding lies in the reduced manufacturing time. The ability to combine different materials in a single injection molding process reduces assembly effort and saves valuable production time. At the same time, optimized process control minimizes rejects and ensures consistently high quality. A 3K connector housing, manufactured in a single step, combines the rigid housing, the flexible seal, and the conductive shield. This technology not only improves product quality but also significantly reduces manufacturing costs.
Sustainability
In addition to economic and functional advantages, multi-component injection molding also offers ecological benefits. The targeted combination of materials reduces raw material consumption and minimizes material waste. Furthermore, the use of lighter components lowers energy consumption in vehicles and machinery.
construction
Our service in the field of multi-component injection molding
In the area of multi-component injection molding, we offer you a comprehensive service package – flexible and modular. You decide whether you want to use individual development services or let us support you throughout the entire product development process – from concept development and tool design to series production.
Our experienced product designers develop precise component solutions according to your specifications – whether as a single component or a complex hybrid component. Optimizing existing designs with regard to function, manufacturability, and cost is also part of our portfolio.
- Design and development of 2K/3K components
- Feasibility analyses for multi-component parts including material recommendations
- Development of technical alternatives for cost and process optimization
- Mould flow analyses to ensure tool and component geometry
- Prototype construction via 3D printing (also multi-material models)
- Creation of detailed DFM (Design for Manufacturing) reports
- Tool design and construction based on your or our designs
This is how we start your project
In order to make you an initial offer, we need the following information:
- Technical drawing, sketch or an existing sample
If you do not yet have a technical drawing, we will be happy to create one for you. - Short product description with area of application
The more details you give us, the more precisely we can tailor the offer to your requirements. - Optional additional information
If available, please send us a specification sheet, technical specifications or special equipment details. - Planned quantity or estimated annual requirement
This helps us to optimally align production to your requirements.
To protect your data and ideas, we can conclude a non-disclosure agreement (NDA) in advance. If you do not have your own NDA, we will be happy to provide you with our template.
We look forward to your inquiry.
Personal Meeting
A personal conversation is particularly important to us when it comes to getting to know each other for the first time and discussing complex or new projects. We want to ensure that we fully understand your requirements and needs and can provide you with the best possible solution.
Of course we are also available to you via email Online meeting available. We use various platforms and tools to ensure seamless and effective communication.
In our Showroom you have the opportunity to see for yourself the quality and functionality of our products, to receive individual advice and to try out the different models. Our team of experts is available on site to answer all your questions and to work with you to find the perfect solution for your requirements.
Contact Simply contact us to Appointment to arrange a meeting and get to know each other. We look forward to it!
Design Guide Plastic Molded Parts & Free Sample Card
Our design guide for plastic molded parts and the two free sample cards in black and white with plastic EDM structures are specifically aimed at developers, designers, and buyers. It offers:
- Practical tips for increasing efficiency and optimizing quality
- Detailed overview of engineering plastics and their applications
- Focus on critical aspects such as material selection and design principles
Our N&H Plastic Sample Cards are made of black and white ABS Plastic manufactured. It contains 12 different SPI surface treatments, classified from A1 to B3, as well as the 12 most common VDI 3400 Surface Textures, from VDI 12 to VDI 45. The scale ranges from highly polished surfaces to highly structured, rough textures, thus providing a comprehensive overview of the available surface structures.
This clear sample card makes it easier for you to coordinate technical requirements with the look and feel of your plastic parts. It helps you make the right decisions at every stage of your project—from planning and development to series production.