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2k Molds

2K molds, also known as two-shot molds or two-component molds, are specialized molds used in injection molding processes to produce plastic parts with two different materials or colors in a single operation. These molds enable the creation of complex parts with multiple features or characteristics without the need for secondary assembly processes. Our mold engineers have rich mold design and engineering experience for 2k molds. Choose us for reliable, innovative, and cost-effective mold-making solutions for your 2K mold projects！

Technical Specifications for Bi-Injection Mold Design and Operation

1. Mold Cavity and Core Configuration

The two female cavities must feature distinct geometries to accommodate separate forming of different products, while the two male cores must maintain identical dimensions to ensure part consistency in bi-injection mold setups.
Critical for double injection mould functionality: Matching core precision prevents flash or misalignment in overmolded components, especially in two shots molds requiring seamless material bonding.

2. Mold Rotation and Alignment Protocol

Implement a 180° central rotation mechanism for front/rear mold halves to ensure precise alignment post-rotation, a key feature of rotation bi-injection mold systems.
Use precision guide pins and locator blocks (tolerance ±0.01mm) to maintain alignment, essential for multi-material integration in 2k mold tooling.

3. Mold Thickness and Installation Parameters

Specify a combined thickness of front mold panel and A-board ≥170mm to withstand injection pressure (100–150 MPa) in bi-injection mold applications.
Perform thorough checks on:

Maximum/minimum mold thickness compatibility with press specifications
KO hole spacing (standard: 200mm×200mm) for ejector system alignment
Platensize matching to prevent stress concentrations in double injection mould setups.

4. Nozzle Design for Automated Demolding

Integrate a self-releasing nozzle system in the plate mold to facilitate automatic sprue separation, reducing cycle time in two shots molds.
Recommend hot runner technology with thermal insulation sleeves to maintain melt consistency (temperature variation ≤±5°C) for 2k mold tooling.

5. Two-Shot Mold Avoidance Features

Design clearance features in the second-injection master mold to prevent damage to the first-molded product’s bond interface, a critical consideration for rotation bi-injection mold designs.
Conduct FEA analysis to validate seal strength under injection pressure (focus on:

Plastic deformation thresholds at high pressure (≥80 MPa)
Crack propagation risks in second-injection zones of bi-injection mold components).

6. Dimensional Compensation for Sealing

Implement slight over-sizing (0.1–0.3mm) on first-injection parts, combined with precision core pressing during second molding, to achieve hermetic seals in double injection mould applications.
Use shrinkage simulation (mold flow analysis) to predict material displacement and optimize press fit in two shots molds.

7. Flow Dynamics and Part Protection

Mitigate plastic flow impact on first-molded components by:

Designing deflector ribs in the second-injection cavity
Adjusting injection speed profiles (ramp-up from 50% to 100% over 0.5s)

Critical for 2k mold tooling to prevent adhesive joint deformation in multi-material parts.

8. Mold Closure Interlock System

Install proximity sensors to ensure front mold sliders and lifters reset fully before A/B board closure, preventing product crushing in rotation bi-injection mold operations.
Set interlock response time ≤0.3s to align with typical cycle times (15–30s) for bi-injection mold systems.

9. Cooling System Optimization

Design balanced coolant channels for both cavities/cores, targeting:

Temperature uniformity (ΔT ≤3°C across mold surface)
Flow rate ≥10L/min for water-based systems in double injection mould setups

Use baffle or conformal cooling in two shots molds to reduce cycle time by 15–20%.

10. Material Injection Sequence Strategy

Adhere to 99% soft rubber deformation prevention by:

First injecting hard plastic components (e.g., PC, POM)
Second injecting soft elastomers (e.g., TPE, silicone)

Optimize melt temperature for hard/soft materials (e.g., PC: 280–300°C; TPE: 180–200°C) in 2k mold tooling to prevent inter-material degradation.

Key Terms Integration Summary

Bi-injection mold and double injection mould systems require precise cavity/core matching.
Two shots molds and 2k mold tooling depend on rotational alignment and cooling balance.
Rotation bi-injection mold designs must prioritize flow dynamics and interlock safety.

This specification ensures functional integrity in multi-material molding, addressing both technical constraints and operational efficiency for advanced injection processes.

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