Thermoforming is frequently employed for producing plastic cups (check the cup overmolding process), including ice cream cups and coffee cups, as well as plastic tubs designed for ice cream packaging.

Throughout production, the accuracy of the molds is checked using a coordinate measurement machine (CMM, a three-dimensional measurement device) to prevent injection molding flaws that can occur from misalignment, such as flash.

Kasirajan puts it simply, “Choose overmolding if the quantity is not too high—only a few thousand or ten thousand—to save some money on molds. If your program requires quantities of 500,000 or more, the more cost-effective process is two-shot injection molding.”

In the case of in-mold labeling, the preprinted labels accompany the plastic sheets during the forming process. The heated sheets are stamped onto a mold, where the printed labels fuse with the plastic.

In contrast, overmolding offers more flexibility with material selection since the secondary material only needs to adhere mechanically to the substrate or use adhesives or primers for chemical bonding. This allows the use of materials with different properties, such as a rigid plastic base with a soft silicone or rubber overlay.It’s not uncommon to need support when reviewing and selecting the right material for your project needs. When requesting an injection molding quote, Fictiv’s global team of manufacturing engineers can provide valuable guidance to ensure your manufacturing success. We also created Materials.AI, a first-of-its-kind AI assistant, to help you navigate the complex landscape of materials choices.

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Blow molding is the preferred process for creating hollow plastic parts. Manufacturers employ this technique to stretch or extrude heated plastic into a mold’s shape. This process has historical roots in glass blowing, and it remains essential for creating various products, especially those requiring a waterproof label integration in molding.

Cost and Volume Efficiency: Two-shot molding is generally more cost-effective at high volumes due to its efficiency and speed, while overmolding can be more suitable for lower volumes or prototypes due to its simpler setup and lower initial costs.

Both two-shot injection molding and overmolding are employed to create multi-material components, enhancing functionality, aesthetic appeal, and product performance. However, they diverge significantly in their methods, applications, and ideal production scenarios.

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Two-shot injection molding often results in a higher consistency and stronger bond between materials, as the process is fully automated and materials are chosen for their chemical compatibility. This can lead to improved structural integrity and performance. Overmolding, while providing good quality and functional enhancements, may face challenges with material bonding if not properly designed, potentially affecting durability.

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The process of two-shot injection molding is executed in a specialized molding machine that is equipped with two or more injection units. The core of the process lies in the precise control of the injection units and the mold design, which needs to accommodate multiple injections. Here’s how it typically unfolds:

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In the world of injection molding services, manufacturers and designers have several techniques at their disposal to create high-quality, functional, and aesthetically pleasing plastic parts. Among the most advanced and versatile techniques are two-shot injection molding and overmolding. Both techniques offer unique advantages and are suited for different applications, yet they are often confused or misunderstood. By understanding the intricacies of each method, professionals can optimize their manufacturing processes and leverage the strengths of each technique for their specific project needs.

In-mold labeling (IML) is a sophisticated manufacturing technique where meticulously cut plastic films, referred to as labels, are seamlessly integrated into the injection mold using a specialized handling unit. These labels are securely affixed in place, often employing a vacuum or a static electricity charge, before being injected with plastic material.

Two-shot injection molding generally becomes more cost-effective at higher volumes due to its ability to produce complex multi-material parts in a single cycle, reducing labor and operational costs. However, the initial investment in setup and tooling is significant. Overmolding, while potentially higher in per-part cost due to longer cycle times and additional labor, requires less upfront investment and can be more cost-effective for smaller production runs.

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Injection molding is a popular way to shape materials like thermoplastics (Check thermoplastic manufacturing) and thermosetting polymers. In this process, manufacturers inject heated, liquefied plastic into a mold through a small opening.

As the plastic cools and solidifies within the mold, it takes on the desired shape. During injection molding with in-mold labeling, a preprinted polypropylene label is placed into the mold. This label fuses seamlessly with the thermoplastic during injection, resulting in a fully labeled plastic product.

The heart of the IML process lies in the injection-molded labeling stage, where precision and attention to detail are paramount. This stage unfolds in the following sequence:

Post-production plays a pivotal role in ensuring that IML components meet essential criteria, including precision, finish, and durability. This may entail rigorous quality control checks, ranging from visual inspections to mechanical testing, all designed to align with specified standards.

Overmolding is used in a wide range of industries due to its ability to add enhanced properties to a part, such as improved grip, aesthetics, and durability. Typical applications include:

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Choosing the right injection molding materials is crucial for the success of both processes. For two-shot injection molding, materials must be carefully selected to ensure they can bond well and withstand the molding temperatures and pressures without degrading. Typically, materials with similar melting temperatures and chemical properties are chosen.

Two-shot injection molding is a preferred choice for many high-end applications in these sectors because it can mold parts that meet strict technical specifications while also addressing the need for visually appealing designs.

Two-shot injection molding is particularly valuable in industries where part durability, aesthetic qualities, and production efficiency are paramount. Common applications include:

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Overmolding is a versatile manufacturing technique where a single part is created through the sequential injection of two or more materials onto a base part or substrate. The primary material, usually a rigid plastic, forms the substrate, while the secondary material, often a softer plastic or rubber, is molded over the first. This process not only enhances the product’s functionality but also improves its aesthetic appeal and tactile experience.

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Now, if you’re new to in-mold labeling, this article will take you through everything related to this injection-molded labeling approach used in modern manufacturing processes. So keep reading to learn all about it!

In both two-shot injection molding and overmolding, thermoplastics are commonly used due to their versatility and ease of molding. For two-shot injection molding, materials like ABS (Acrylonitrile Butadiene Styrene), polycarbonate, TPE (Thermoplastic Elastomers), and TPU (Thermoplastic Polyurethane) are popular. These materials are chosen for their ability to bond well during the molding process and withstand the rigors of repeated use.

Overmolding frequently uses similar base materials, such as ABS and polycarbonate, but often pairs them with softer, more flexible materials like silicone or soft PVC. These combinations provide enhanced grip, aesthetic qualities, or additional functionality, such as shock absorption or water resistance.

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Two-shot injection molding, also known as dual injection, multi-shot, or 2K molding, is a highly specialized process that combines two different materials or colors into a single injection molded part. This advanced molding technique involves injecting two types of polymers into the same mold through separate injections but within the same molding cycle. The result is a complex part that can have varying colors, textures, or material properties, seamlessly integrated without the need for post-molding assembly.

Subsequently, a precise combination of heat and pressure is applied to melt the substrate film, seamlessly merging it with the plastic material within the filling and holding cycles. Notably, this innovative technology is frequently employed alongside stacking molds, boosting production rates while consistently delivering top-notch quality and reproducibility.

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The post-production phase of IML encompasses a series of meticulous steps geared toward upholding quality, consistency, and adherence to design specifications. This phase involves tasks such as flash removal, final product packaging, and preparation for subsequent assembly processes.

Pre-production encompasses the meticulous preparations made by manufacturers and designers before venturing into the injection-molded labeling phase. These preparations play a pivotal role in determining material selection, label alignment, machine setup, and more, all of which significantly impact the final product’s quality.

Deciding between two-shot injection molding and overmolding depends on several factors, including the project’s scale, budget, material requirements, and final product application.

The versatility of overmolding makes it ideal for customizing parts that require tactile and aesthetic qualities in addition to functional performance. This method is especially beneficial where the production scale or budget constraints do not justify the higher initial costs associated with two-shot injection molding.

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When considering IML, you might often come across the terms IMF (In-Mold Film) and IMR (In-Mold Decorating). To avoid any confusion, it is important to understand what they are and how they are different from IML.

The IML process unfolds through three pivotal stages: pre-production, molding and labeling, and post-production. While the labeling during molding stage takes center stage, understanding the nuances of pre-production and post-production is pivotal to ensuring the production of high-quality IML components.

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Two-shot injection molding typically has shorter cycle times because it completes the part in one continuous, automated cycle. Overmolding requires multiple cycles (one for each material layer), potentially increasing total production time, especially if manual labor is involved in transferring substrates between molds.

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By thoroughly assessing the requirements of your specific application and considering the pros and cons of each method, the injection molding experts at Fictiv can help you select the most appropriate injection molding process to achieve your manufacturing goals.

In-mold labeling stands as a cost-effective and efficient method for rapidly manufacturing labeled containers. Its durability, resistance to wear and tear and waterproof nature make it an ideal choice for embedded labeling molded containers.

The entire process is highly automated and controlled, requiring less labor and minimizing the risk of human error, which is crucial for the high-volume production of complex parts.

When seeking in-mold labeling solutions, entrusting your projects to Prototool is the key to unlocking the full potential of this process.

Compared to IML, IMF is also quite similar. However, instead of labels, it uses printed plastic films with designs. These films are carefully put inside the mold and blended with the melted plastic as it shapes into the final product. IMF is known for its ability to create intricate and colorful designs on various plastic items.

Ashwin Kasirajan is a Fictiv Manufacturing Engineer who works with customers on their injection molding programs. To understand the importance of tool design in two-shot injection molding, he explains, “The tool must allow both stages of the part to be molded in the same tool in order to achieve maximum production efficiency. The design must consider two separate injection stages that can be rotated 180 degrees or oriented to allow a robot to transfer the components. Each injection station is run by an independent injection unit, which allows injection speeds and pressures to be controlled for each material being utilized.”

Kasirajan also points out the importance of precision throughout the process, “Because the mold shifts or rotates along the axis, the interchangeability of the core and cavity at both sides must be ensured.”

Precisely, in-mold labeling focuses on putting preprinted labels made of strong polypropylene into a mold before plastic is injected. As the plastic takes shape in the mold, it merges with the labels, creating a single product with labels already in place. It’s great for making visually appealing and well-labeled plastic items.

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As the plastic cools and solidifies, the label becomes an integral part of the product. This method is commonly used for liquid containers, such as those for liquid soaps, shampoos, dishwashing detergents, ketchup, and sauces.

Overmolding offers more design flexibility due to its ability to combine a wide range of materials that do not necessarily have to be closely compatible. It allows for the addition of different textures, colors, and properties with fewer constraints on the molding environment. Two-shot injection molding is precise and efficient for producing complex, multi-material parts. However, material compatibility and design precision are required for the positioning and bonding of materials.

“However,” he advises, “depending on the part’s structure, some features can only be accomplished by double-shot injection molding, while others can only be completed by overmolding.”

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As we compare overmolding to two-shot injection molding, understanding their specific applications and the subtleties of each process will be crucial in determining the best approach for any given manufacturing requirement.

In contrast to the two, IMR takes a different approach. It uses a decorated or printed film that’s placed on the mold’s surface. When plastic is injected into the mold, the design of the film transfers onto the plastic product’s surface. IMR is perfect for achieving high-quality and finely detailed graphics on the product’s exterior.

To sum it up, IML focuses on integrating labels, IMF uses printed films inside the mold, and IMR uses decorated films on the mold’s surface. Each method has its unique advantages, so it’s important to choose the right one for specific production needs.

Thermoforming differentiates itself from the previous processes by using heated plastic sheets rather than fully melted plastic. Manufacturers rely on heated plastic sheets and a forming tool to shape containers.

In blow molding with in-mold labels, the extruded plastic is introduced into a hollow tube, which is then captured in the mold. Air is blown into the tube, causing it to take the mold’s shape. The mold’s inner wall contains a polypropylene sheet with printed or embedded labeling.