FCS: Two-component Injection Molding Machine Is the Future, and Will Step towards Large Scale and Precision!

In recent years, multi-component injection molding technology has been widely adopted in line with the development of industrial technology. Since 2000, four major developments have taken place in two-component injection molding machine technology: large scale, precision/specialization, multi-component and multi-function, and verticalization of rotating axis.

Precision / specialization of two-component machines
The precision of two-component injection molding machines is mainly reflected in the use of oil-electric hybrid two-component machines, which are less expensive than the electric ones, but can effectively overcome the drawbacks of the traditional oil-pressure type including high energy consumption and poor precision, and significantly reduce pollution and noise. 

In addition to the precision of the injection unit, the continuous optimization of the rotating structure is another major breakthrough in two-component injection molding machines. Whether it is the rotary table or the shaft, from the earliest rack structure, to the hydraulic motor drive, and then to the servo-electric drive, the rotating speed and precision have been greatly improved.
Two-component injection molding machines are industry-specific and have a high degree of customization.

Since 2000, two-component injection molding has been used in the mobile phone industry, auto parts industry, electrical and electronics (E&E) industry, cosmetics and medical applications, and other industries, showing a trend of specialization.

Photo / Multi-component products of two-component injection molding machine

Multi-injection / multi-function of two-component machines
The development of multi-component injection molding machines started with two-component injection molding machines. As the complexity of products increased, the demand for three-component and even four-component injection molding machines began to emerge.

From the technical point of view, the precision of multi-station rotary table control is higher than the two-station one, so the production cost of the machine is relatively high. Therefore, it is not necessary to blindly pursue multi-station multi-component injection molding machines, but to choose the most effective solution according to the product structure requirements.

In terms of multi-function, it is the mobile function of the injection unit that really makes the multi-component injection machine have various functions and flexible production mode.
Multi-functional molding machine is an excellent choice for enterprises that tend to diversify their products. Take the automotive lighting industry as an example. With the configuration of injection units, a single multi-component machine can be used to produce both headlights and taillights.

For example, the FCS Large Horizontal Rotary Table Two-Component Injection Molding Machine (HB-R Series) is designed to produce two sets of two-component injection units for large home appliance shells and panels, automotive sunroofs, headlights, corner windows and other two-component products. The machine can be used for both single-component and two-component products.

Photo / FCS Large Horizontal Rotary Table Two-Component Injection Molding Machine (HB-R Series)

From the analysis of the exhibits at the major comprehensive injection molding exhibitions around the world in the last decade, there are various combinations of multi-component molding technologies. For example, two-component + IML (In-Mold Labeling), two-component + IMA (In-Mold Labeling), two-component + stack mold, two-component + rotating stack mold + IMA, two-component + IML + IMA + stack mold, two-component + interlayer, two-component + MuCell, three-component + IMA, etc.

In other words, multi-component molding technology must be combined with other technologies to create higher efficiency. This is the goal we have to achieve in the next stage.

One of the key issues is the development of multi-component molding technology and auxiliary automation, whether it is in-mold labeling, in-mold assembly, horizontal rotating four-sided stack mold, MuCell, and silicone molding, all need the assistance of related molds and auxiliaries.

Therefore, the technical integration and joint development of injection machines, molds and peripheral automation are the key to the improvement of multi-component injection molding technology and the formation of highly automated production units.

In the future, the application of horizontal rotating four-sided stack mold, combined with electric drive units, such as rotating units and injection units, is also an important basis for multi-component injection molding machines to achieve high precision and multi-function.

With the advancement of intelligent injection molding technology, multi-cavity flow balance, melt variation adaptive control system, online monitoring of clamping force and other applications allow multi-component injection molding machines to gradually develop towards high performance. 

Know more: FCS Total Solutions

Summary: 
China has the largest automotive market and the largest injection molding machine business. It is expected that two-component injection will play a greater role in the era of Industry 4.0 and the era of intelligent driving.

Introduction of Large Horizontal Rotary Table Two-Component Injection Molding Machine (HB-R Series)
1. A horizontal rotary platen decreases issues coming from gravity and inertia.
2. Its swivel unit provides quick positioning and is equipped with numerous safety features.
3. High loading capacity and self-supporting swivel unit to hold a maximum mold weight of up to 30 tons. Suitable for two-colored, large products like automotive exterior components.
4. With a special process integration, such as a special four-sided mold, then can form a stack mold.

Photo / HB-R Series can form a stack mold with a four-sided mold.