Ao discutir moldagem de dois disparos versus sobremoldagem, é muito fácil confundir os dois processos. Eles fornecem vantagens comparáveis na produção e têm várias características semelhantes. Para alcançar os melhores resultados, você deve tomar nota de várias diferenças significativas. Você pode escolher a melhor solução para seus projetos, entendendo as distinções entre moldagem de dois tiros e sobremolagem.
A moldagem por injeção abrange uma ampla gama de procedimentos, incluindo moldagem de dois tiros e sobremoldamento. Aqui estão as diferenças fundamentais entre esses dois processos que os engenheiros e designers precisam estar cientes:
O que é moldagem de dois tiros?
Moldagem de dois tiros, Às vezes chamado de dupla tiro, Multi-shot, ou moldagem dupla, é um subtipo de moldagem por injeção que permite aos engenheiros produzir componentes com vários materiais ou cores sem adicionar processos adicionais de montagem.
A maneira mais simples de compreender o procedimento de moldagem por injeção de dois tiros é pensar nas várias camadas de materiais ou cores que a máquina de moldagem por injeção produz.
Como funciona a moldagem de dois tiros?
Para produzir o substrato, que o outro material ou materiais serão moldados ao redor, a primeira substância é injetada em um molde. Antes de ser movido para a câmara oposta do molde manualmente, Braço de robô, ou plano rotativo, o substrato endurece e esfria.
O molde então abre, permitindo que o lado do substrato gire 180 graus e encontre a câmara de molde oposta e o bico de moldagem por injeção. A segunda substância é injetada após a implementação do substrato e se liga ao substrato para criar uma aderência segura. O último componente é removido quando a segunda camada esfriar.
Benefits of 2-Shot Injection Molding
Particularly in high-volume manufacturing circumstances, double shot molding is the best procedure for complicated, multi-material, and multi-colored plastic items. Additional benefits include:
- cheaper per unit.
- decreased waste and costs related to assembly failures.
- improved product caliber.
- Extremely flexible production capacities.
- Better quality control and reduced waste
Common Applications
Para complicado, multi-material, and multi-colored goods, double-shot molding is excellent. It is a very flexible approach with several uses across numerous sectors, Incluindo:
- movable components or parts
- auto interior components
- surgery and medical equipment
- kitchen utensils and bottle fillers
- buttons on a panel with a soft grip
When to Use 2-Shot Injection Molding Manufacturing
The greater upfront expenditures and more expensive, specialized technology associated with 2-shot injection molding are some of its most major disadvantages. No entanto, these expenses are often covered throughout manufacturing by labor, resource, and assembly cost reductions. This makes 2-shot injection molding a good choice for large-scale manufacturing runs. It is also a great option if flexibility, quality control, and efficiency are your top priorities.
What is overmolding?
Overmolding is the technique of covering an existing component or piece with an extra layer of material. This method is frequently used to create components, parts' sub-sections, and to produce prototypes. Tipicamente, the overmold material is shot into or around the substrate after the substrate material (the initial component of what will be bonded and mechanically interlocked with additional materials) is inserted into an injection molding tool. The two materials are bonded together to form a single component when the overmold materials harden.
Advantages and disadvantages of overmolding
You can truly use any kind of plastic if you are overmolding a metal component with plastic. There may be compatibility concerns if you are overmolding one plastic component with another plastic. Your knowledgeable molder will be able to suggest the ideal materials for your project.
By including important functional elements and adding texture, color, and overmolding, one may alter the surface of a piece or product. Additional benefits include:
- Multi-material components and improved design flexibility.
- reduced labor costs, ancillary activities, and assembly.
- enhanced component structure and strength.
- Cost-effective operations.
Overmolding has a lot of advantages, but there are also certain drawbacks that should be taken into account before using this technique.
Overmolded pieces are created using a multi-step, two-step technique. Como resultado, it is more costly to mold a single component without overmolding and lengthens the part cycle time. Adicionalmente, two tools are needed, or a complicated two-shot mold with a higher initial investment. Overmolding becomes a value-added alternative, nevertheless, when the alternative is to produce two distinct injection-molded pieces and then combine them afterwards.
Delamination can happen when two distinct materials are bonded together in an injection mold. This frequently occurs when the temperatures are outside of what is ideal for the particular material combination. When materials cannot be properly bonded together using heat, mechanical interlocks may occasionally be necessary.
When to Use Overmolding for Manufacturing
Similar to 2-shot molding, overmolding injection molding is perfect for any application that requires goods with additional functional components, numerous colors, or different textures. Low-volume runs of thermoplastic or rubber goods that do not need to adhere to exact tolerance specifications are best suited for this service. Since overmolding services may be carried out on any common injection molding production equipment, overmolding is also a great option for enterprises that don't want to invest in new technology.
Choosing Two-Shot Molding vs Overmolding
Many of the benefits of overmolding and two-shot injection molding are similar. Both are excellent for swiftly producing components with complicated geometries that are robust, dependable, and vibration-resistant, although overmolding is better suited for low-volume production runs.
Overmold designs are also simpler to create than two-shot designs since engineers may utilize any common injection molding equipment to carry out this technique.
The tolerances of products produced via overmolding are frequently less precise than those possible with two-shot injection molding, which is a drawback. It's also critical to keep in mind that requirements for plastic compatibility might impose limitations on designers.
Overmolding is preferable for low volume production runs, but two-shot molding is typically only practical for larger production runs. To make the best decision, As equipes ainda devem fazer a devida diligência e comparar todos os fatores importantes de cada método de fabricação concebível com as necessidades de seus projetos específicos.