Overmolding, insert molding, multi-component injection molding, injection molding MuCell®-technology  can offer flexible solutions for the integration of functions as well as the production of medical assemblies. Through various printing and marking technologies (e.g. laser marking), surface treatments, deburring technologies (e.g. blasting), custom requirements regarding haptics, optics and traceability are met.

The 2K injection molding process is mainly used for products that have to meet several special function or appearance requirements. For example, some products must be waterproof, drop-resistant, and dust-proof. Other products must have a variety of colors on the surface to meet aesthetic requirements. Some products may also require a good grip and touch. This includes realizing effects such as a soft-touch surface, an ergonomic design, a two-tone appearance, watertightness of a product, shock absorption, moisture resistance or making plastic parts anti-slip.

Compared to instruments made of metal, such components allow X-ray transparency, are non-magnetic, lighter and can also be colour-coded. In addition to cutlery and applications in the operating theatre, such medical injection molded components are used in neurosurgery, e.g. for head mounts or also as trial implants.

All these applications place the highest demands on tolerances, feel and appearance of the medical plastic injection molded parts. The low weight of the plastic instruments contributes to gentle handling even during longer periods of use.

A disadvantage of 2K injection molding is that the costs for a mold are higher than a mold for 1K injection molding. Furthermore, the injection molding machine must be equipped with a second plastic component, which also makes the machine more expensive. Ultimately, with 2K injection molding, the costs are recovered by reducing labor and assembly costs, because the manual application of, for example, a seal is no longer necessary. This avoids an assembly step.

It is estimated that 99% of all plastics are made from fossil fuels such as oil and gas. The remaining 1% is made from natural

The raw material granulate granules are supplied in a wide variety of types, colors, and designs. In order to influence properties or color, the producer

In medical technology, some components also require individual machining to achieve special contours and accuracies. Injection molding of blanks significantly increases the material variety and selection options. In addition, material losses and thus costs can be significantly reduced through near-net-shape injection molding.

2K injection molding is a production process in which two materials (colors) are processed in one plastic part. This plastic molding technology combines two materials or two different color materials into one ending plastic part using a 2K injection molding machine.

In the Transition Agenda for Plastics, we have jointly set ourselves the goal that by 2050 the extraction of new raw materials will take place

The chemical bonding process involved in this happens because they are capable of joining two or more materials into one part. When using a 2K injection molding technology process, the choice of material will be the most important factor for the project’s success. Two completely opposite polymers can be used for a ready-to-use product.

The choice of material is very important, as different plastics have different physical properties. The plastics that are processed together must be compatible with each other and the difference in shrinkage of the two plastics should be small.

Our injection molded medical products are used, among other things, in diagnostic and operating theatre equipment, where they take over important mechanical functions, such as dry lubrication, reduce wear and, of course, ensure the necessary mechanical strength.

In addition to 2-component injection molding, it is also possible to process three types of plastic into one plastic part. This is called 3K injection molding.

With our comprehensive portfolio of Medical Grade MT materials, we offer a very high variety of materials in injection molding in medical technology and thus excellent choices for individual applications.  In addition, we offer extensive injection molding materials expertise for an application-specific material development with in-house compounding.

Long-term resistance to X-rays and continuous operating temperatures of 260 °C, e.g. for computer tomography (CT), can be achieved with injection mouded components made of high-performance medical plastics.

We can injection mold our own thermoplastic composites into medical components that are used, for example, in operating theatre robots.

For decades, we have been developing and manufacturing durable medical and surgical instruments with specific requirements for cleaning, disinfection or sterilisation, chemical resistance and the necessary mechanical strength, surface quality and freedom from burrs using plastic injection molding and as assembled subassemblies.

Another disadvantage of 2K injection molding is that it makes the recycling of the plastic products difficult, because often two different plastics are combined. Even when the plastics are “from the same family”, the quality of return flows will be less. This makes it difficult to reuse the plastics for a high-quality application.

We have many years of experience in the production of such blanks and can also reliably injection mold larger wall thicknesses without cavities.

We realise the complex shapes and design geometries required for this with high precision and efficiency using our injection molding technologies.