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On the road of pioneering multi-component injection molding technology, FCS has a promising future!

In recent years, multi-component injection molding technology has received increasing attention due to advantages such as high production efficiency, power saving and environmental protection, and high added value of products. It is applicable to a lot of industries, including automobiles, mobile phones, pens, electronic appliances, hand tools, daily necessities, construction, packaging and medical equipment. At the same time, as domestic and foreign companies are also increasing research on multi-component injection molding, new equipment and new technologies emerge one after another. For example, the technology of two-component/multi-component/multi-material/multi-angle injection molding has been developed and has made considerable progress, which has become the focus and hot spot of the injection molding industry in recent years.


Click to knowing the types of FCS “muti-injection” molding machine


FCS_knowing the types of FCS “muti-injection” molding machine



Product Diversification and Differentiation Are Gradually Formed

The advanced two-component injection molding machines developed by FCS include rotary type, rotating shaft type, electric type, sandwich / interval injection molding machine. After the strict test of market customers and actual machine verification,FCS has formed four series covering more than 30 specifications, and the clamping force ranges from 135 tons to 3,300 tons. They are widely applied in a wide range of industries such as automobiles, mobile phones, laptops, pens, hand tools, high-end daily necessities, cosmetics, and home appliances.


Hsiao-Chou Chen, Technical Manager of FCS Ningbo
Photo: Hsiao-Chou Chen, Technical Manager of FCS Ningbo


Hsiao-Chou Chen, manager of the Technical Department of FCS (Ningbo) Machinery Manufacturing Co., Ltd., said in an interview with Jufeng that the two-component injection molding technology is developed on the basis of the single-component single-material technology. It is the result of market demand for the purpose of replacing manpower with machines and improving the production efficiency of two-component parts and the quality of the combination of different materials. In the past, there were also inlaid metal material molding and twice/three-time molding. The disadvantages of these technologies lie in that they consume a lot of manpower and material resources, occupy production space, and it is difficult to guarantee the quality of recombination after cooling.


Since 2005, due to the emergence of labor, production capacity and mass customization, multi-color and multi-component technology has been vigorously developed in Taiwan. At that time, there were two well-known European manufacturers of injection molding machines in the world with outstanding strength in multi-component and multi-material injection molding technology, but their application field was also limited to the automotive industry, and they did not take multi-component injection molding technology as a key point to develop.


FCS has set the direction of special customized multi-component injection molding machines.As FCS actively explores and develops the technology, it has increased the tonnage of machines from 260 tons to more than 3,000 tons and introduced the modular concept. The clamping mechanism is taken as the core and the injection mechanism is available in the form of a package, which greatly shortens the delivery cycle time and puts forward strict requirements on the Company's software and design capabilities.


In February 2018, FCS participated in the China Plastics Machinery Industry Association's Group Standards Working Committee and served as the first company to draft Group Standards of “Multi-component Plastic Injection Molding Machine”. The Group Standards were officially released in the summer of 2020, which was an important milestone in the development of multi-component injection molding technology in China. It ended the chaos of standards by many manufacturers, formed unified standards and even standardized molds, reduced disorderly competition and waste of resources, and brought the development of multi-component injection technology to a new level.


Multi-component injection molding technology has gradually matured, and manufacturers of high-end products such as auto parts have fully accepted the corresponding cost input brought by the application of multi-component injection molding technology. Although temporarily it’s hard for some manufacturers of lower-end products to bear the cost, they will eventually embark on the road of replacing manpower with machines, which is just a matter of time.


FCS_Traditional factories are gradually moving towards modernization.
Photo:Traditional factories are gradually moving towards modernization.


In 2015, FCS began to cooperate with Colgate-Palmolive. Four years later, in 2019, the production capacity of more than 300 single-component injection molding machines applied by users before were replaced with the capacity of 22 two-component injection molding machines. The labor force was reduced from more than 6,000 in 2019 to more than 1,100 now. The effect of replacing manpower with machines is immediate and obvious. In addition, a foreign supplier who supplies IKEA, applied one production line of FCS to replace the previous six production lines, creating higher profits for customers with super high price–performance ratio. In the long run, multi-component and multi-material injection molding technology must be an important direction of the processing and development of the injection molding technology.Not just the concept of plastic will be developed in the future. When plastic and metal powder are injected and molded together, for example, the car lights of BMW electric cars are directly embedded in the bumper for integral molding, eliminating the subsequent installation steps. A type of FCS’s horizontal injection molding machines developed for this application were widely welcomed in the market and became benchmark machines in this field.


FCS_Large Horizontal Rotary Table Two-Component Injection Molding Machine (HB-R Series) is widely used in automobile and home appliance industries.
Photo:Large Horizontal Rotary Table Two-Component Injection Molding Machine (HB-R Series) is widely used in automobile and home appliance industries.


When the reporter mentioned the gap between FCS's multi-component injection molding technology and the international advanced ones, Hsiao-Chou Chen believed that there is almost no gap.The core competitiveness of FCS lies in the ability to quickly adapt to the market and meet the needs of customers, for FCS can provide more models for users to choose and better meet the diversities of molds so that the expandable space is greater.These strengths are not achieved overnight. Instead, FCS has experienced long-term experience accumulation. Special technologies require more technical reserves, and FCS has been striving for them. For example, the integrated car light project, in fact, has been prepared for 10 years. In addition, the equipment developed by FCS now is also actively prepared for the market in the next 5 years or even 10 years. As Hsiao-Chou Chen said, the R&D expenses of FCS accounts for as much as 20% of the Company’s output value, which is unparalleled in the industry. The mission of FCS is: "To lead the development of China’s multi-component injection molding technology, constantly promote the application of multi-component injection molding technology, become the best alternative brand for imported machines and create higher benefits for customers."


Hsiao-Chou Chen predicted that a major trend in the plastics industry in the future is that there will be more demand for large-scale personalized customization. If expecting to achieve rapid production, the industry needs multi-component injection molding production.It is an inevitable trend to input requirements for different colors and different materials in the front-end computer to change colors and appearance.


The state of full-load production of FCS has lasted for 5 years. In the future, the Company will change the multi-component injection molding technology from the rough type to the more refined and specialized one, and develop the products in the direction of "large-sized and electrified", to lead the industry to standardization development.


He said that the FCS’s new production base in Hangzhou Bay is prepared for intelligent production of “large-sized and electrified” multi-component injection molding equipment, and has reserved a model factory that will apply 5G technology to organize modern production. On the road of pioneering multi-component injection molding technology, FCS has a promising future!


>>Groundbreaking Ceremony of FCS New Factory In Hangzhou Bay New Dist



The Development History of FCS Two-/Multi-component Injection Molding Machines

In 1984, FCS launched the first-generation two-component injection molding machines KT-300D. It was one of the few manufacturers that could produce two-color injection molding machines at that time.

FCS first-generation two-component injection molding machines KT-300D in 1984.
Photo:FCS first-generation two-component injection molding machines KT-300D in 1984.


In 1990, FCS's most representative two-component injection molding machines were the FB series. Today, "FB" has almost become synonymous with two-component injection molding machines, which reflects their profound influence.
FCS Ningbo plant were established in December 2001; FCS launched large-sized two-component injection molding machines (FB-1000R) with a clamping force of 1,000 tons and a rotary diameter of 1.6 meters.

In 2005, FCS Ningbo received an order for two-component injection molding machines with CE specifications from a German electronics company. For FCS Ningbo, this was the first order of two-component injection molding machines sold to Europe. In the same year, FCS launched the FB-450M three-component injection molding machines, and FCS was one of the manufacturers of three-component injection molding machines at that time.

From 2006 to 2010, FCS achieved mass production of large-sized two-component injection molding machines with a clamping force of 700 tons to 1,420 tons in China, and by 2015 it had increased the tonnage to 1,900 tons.

In 2007, FCS launched the servo hydraulic two-component injection molding machines, opening the way to manufacture high-precision and power-saving multi-component injection molding machines.

In 2012, FCS launched the large horizontal rotary table two-component injection molding machine (HB-1900R) with a clamping force of 1,900 tons. This kind of machine model won both the 2013 Ringier Technology Innovation Award and the 2017 Taiwan Excellence Award.


Photo: FCS launched large-sized two-component injection molding machines (FB-1000R) in 2001
Photo: 2001 Large-sized two-component injection molding machines (FB-1000R)
Photo: FCS launched the large horizontal rotary table two-component injection molding machine (HB-1900R) In 2012.
Photo: 2012 Large horizontal rotary table two-component injection molding machine (HB-1900R)


In 2014, FCS launched the second-generation two-component injection molding machines of the FB series, which comprehensively upgraded the specifications that less than 400 tons, optimized the structural rigidity and the movement performance of the rotaries and added more injection unit options.

In 2017, FCS completed the development of a full series of electric rotary multi-station three-component injection molding machines with a clamping force of 160 tons to 1,900 tons, and they have been widely applied in the market.

In 2018, driven by the automobile industry, home appliance industry and laptop industry, FCS shipped more than 60 large-sized two-color injection molding machines each year, which suggested that the application of large-sized two-color injection molding machines in the Chinese market has entered a mature stage.



 

 
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