Kemal’s facilities cover 8500 square meters. We have 180 staff, including 30 experienced engineers, and 80 skilled toolmakers working to HASCO, DME & LKM standards.

Another over-mold technique utilizes a transfer injection tool that employs hot runners to mold the substrate, and then transfer it to the LSR side where the material is delivered via cold runners. A ready two-shot part is automatically de-molded using robotic technology. This process creates a mechanical, thermal, chemical or a combination of a chemical and mechanical bond between the two materials.

Kemal takes responsibility for the quality of each mold. That extends as far as signing a mold quality warranty with customers for each tool.

You can request an instant quote from our quotation form. Our expert team will reach out to you within 24 hours to provide consultation throughout the process.

LSR two-shot injection molding produces high-performance lightweight parts and reduces production time — all of which add to your bottom line.

Are you seeking the best-quality injection molding services for rapid custom plastic prototyping? With our fast quotation service, get free injection molding quote and design feedbacks from experts.

Kemal offers proficient technical assistance round the clock, backed by a proficient team of skilled engineers and technicians.

Our manufacturing process adheres to a stringent quality control system that guarantees exceptional prototypes and production parts.

Today, blended TP and LSR components make up products ranging from consumer electronics and automobiles to medical devices and industrial/defense assemblies. Companies, across a variety of industries, can produce complex, precision LSR components in high volumes and parts that meet the most demanding applications.

Although manufacturers have some experience with thermoplastic or liquid silicone rubber applications, many do not grasp the significant advantages of combining the two materials. This is especially true in an era of intense global competition, tight budgets, and mandates for leaner operations and improved customer satisfaction. LSR two-shot injection molding offers companies the best features of using thermoplastics and liquid silicone rubber to make their parts.

Some manufacturers utilize a method that fabricates the substrate, and then, using robots, transfers the part to a second injection molding machine, which over-molds the piece with an elastomer and a second polymer.

In case the parts do not conform to the specifications, please reach out to us within five business days of receipt, and we will resolve the issue within 1-3 business days.

The multi-molding injection process plays a significant role in changing the design, aesthetics and functionality of parts and products across a broad range of industries. The technique is becoming increasingly appealing because it allows companies to develop complex parts, create textured or soft-touch grips for products, produce two-color aesthetics, give products ergonomic attributes and provide designers and engineers with so much more flexibility to create a diverse set of products.

Support for the very highest standards and technical requirements. For example, we support ISO8 cleanroom injection molding.

For example, air entrapment can become an issue. An expert would understand the possibility of air entrapment in a cavity and the importance of making allowances for the fact that LSR injects at a lower psi — 1,000 to 2,000 psi — and thermoplastic injects into the mold at 20,000 to 40,000 psi.

The two-shot (2K) injection molding technique is the ability to create injection-molded parts by forcing two different materials into different locations in the same mold. Consequently, a minimum of two shots are injected into the mold as compared to the single injection common in traditional injection molding methods. Often, the term “Two-Shot Injection Molding” and the use of associated expressions have caused a bit of confusion about the process.

At Kemal, we’re dedicated to bringing your injection molds related ideas to life. Our team of creative plastic molds manufacturing experts is always available to execute your project in the most efficient ways.

This two-shot injection molding guide can assist you in your understanding of the process and how your company can use its capabilities to help you produce high-performance parts efficiently.

For instance, some manufacturers used the term to describe the insert molding process, which entails the placement of an insert into the injection mold prior to molding. Then, melted plastic material is injected into the mold to fill the cavity and mold around the inserted part. The insertion technique is also used for metal/LSR parts integration. The metal undergoes cleaning and pre-treatment before feeding the metal substrate directly into the LSR injection-molding unit.

From prototyping to production, Kemal is dedicated to delivering superior quality and reliable functionality. Our extensive range of production-grade metal and plastic materials, combined with highly advanced on-demand manufacturing techniques, enable us to offer high-quality products across several industries.

At Kemal, we take pride in our ISO 9001:2015 certification, which demonstrates our commitment to producing consistently high-quality products. Throughout our production lines, we strictly adhere to ISO standards, while our rapid prototyping and production lines incorporate cutting-edge technologies for accuracy and precision. Our sophisticated in-house testing and measuring tools guarantee that every component meets your specifications.

The uncertainty has to do with the wide range of multi-material applications that go beyond the using of soft materials on rigid substrates. The lack of clarity may also result from the properties of the molded component or base process.

After the trial phase, we provide low-volume production service to ensure precision with efficient machinery under expert surveillance, saving time and cost.

Learn how Kemal manage the whole manufacturing process of Injection Mold and complete your order on budget and on time, batch after batch.

Other industries that utilize LSR two-shot injection molding include telecommunications, construction, electronics, household appliances, food and beverage, as well as other sectors.

The design of a multi-shot component begins with providing the answers to some some basic questions about the use of the part, the environment in which the part must operate and the desired characteristic of the final product.

With a wide array of manufacturing capabilities, Kemal provides precision machining of exceptional quality. Our on-demand manufacturing services cover everything from prototyping to mass production, allowing us to produce products with complex geometries and high aesthetic demands. Our team of skilled experts, together with our advanced technologies, make this all possible.

Another approach uses automation to expand the original cavity geometry by employing retractable (movable) slides or cores while the substrate remains in the mold. Referred to as core-pull or core-back, the core retracts after the solidification of the insert, which creates an opening in the part that is filled with a second resin contained within the same mold.

The TPEs most commonly employed in the multi-shot molding process includes Polypropylene (PP) and Polybutylene Terephthalate (PBT). Other material options include:

From quotation to final production, acknowledge the seamless order process at Kemal. Our qualified team ensures you get your plastic molded parts within the provided lead times.

Trust Kemal to turn your concept into reality through our exceptional on-demand manufacturing services. We have powerful and efficient manufacturing capabilities that allow us to produce both simple and complex prototypes and end-use parts. Our adherence to strict tolerance criteria and quality standards has helped us become China’s leading on-demand manufacturing company.

Two-shot molding has inherent characteristics that make it a relatively easy operating process, but there are still factors that must be considered to ensure the most efficient operation:

Working with our experts having 20+ years of experience in the injection molding industry, efficiently complete a turnaround from prototyping to production.

We offer greater development and production efficiencies to help our customers, which include Fortune 100 companies across a wide range of industries, to minimize both short- and long-term production costs. Contact a SIMTEC representative to learn how you can get the highest performance possible from your two-shot injection molding parts.

In many applications, Fluorocarbons, EPDMs and other thermoset compounds are not suitable for 2-Shot molding. It is only natural that companies would want to benefit from combining LSR/thermoplastic materials. However, the thermoplastic material must have the elastomeric and thermoplastic properties that allow the material to withstand temperatures of 300-degrees F or more and are able to co-polymerize to the LSR material.

Material compatibility will be one of the primary keys to the success of your 2-Shot molding component and ensuring it meets the necessary criteria. LSR has grown into a popular choice as a material for liquid injection molding processes because it outperforms TPEs (and other options) in a number of areas, including:

Kemal delivers high-quality precision machining with an incredible range of manufacturing capabilities. From prototyping to mass production, we help manufacture products with complex geometries and high aesthetic demands. Our skilled experts and advanced technologies allow us to deliver an extensive range of on-demand manufacturing services.

In order to determine the most suitable molding technique, you must consider a number of factors, including part shape and geometry, production volume and quality requirements.

The industries and applications that use multicomponent injection molding continue to grow across a variety of end-user markets, including:

With nearly 30 years of experience, Kemal supports customers with rapid prototyping, mold making, injection molding, and CNC machining for the automotive, medical, electronics — in a convenient, one-stop solution.

Early on in the design phase, it is critical to work with an experienced two-shot, LSR-thermoplastic manufacturer. Collaborating with the right designer and/or manufacturer assures you have the critical understanding needed to address the relationship between material, parts and the final end-use performance of the part. The manufacturer should also be experienced in silicone molding and material compatibility.

SIMTEC has a global reputation for our expertise on the liquid injection molding process, including two-shot injection molding. Unlike other manufacturers, our single focus is the liquid silicone rubber injection industry. Our design and technical capabilities allow us to provide the assistance you need from initial concept to final production.

The part designer and engineers must also determine how long the part must meet these performance specifications to perform correctly.

We use preferred material for mold tooling production to provide premium-quality and tailored mold tooling that perfectly fits your application’s specifications.

The primary challenge of any 2-Shot molding application is the achievement of maximum adhesion between the TPE and LSR materials. Proper adhesion requires a thorough understanding of the materials and the related nuances of molding of these materials. When designing the over-molded component, product designers and engineers must evaluate different material characteristics and behaviors under processing to optimize cost-per-unit production and to assure end-use performance reliability.

Once the thermoplastic and LSR materials are selected, the 2-Shot molding of the component is achieved through the combination of the most efficient product design, mold design, material chemistry and manufacturing process.

In the past, long-term adhesion when using the multi-molding process for molding of TPEs onto rigid thermoplastic substrates or over-molding LSR on thermoplastics was a major challenge for manufacturers. However, advances in the development of self-adhesion LSR material make it possible to use certain grades of LSR that bond with thermoplastics. Self-adhesive LSR eliminates many of the processing steps of substrate preparations, such as plasma, UV light treatment or chemical primers.

For example, perhaps the part specifications require the rigidity of a thermoplastic and the soft flexibility inherent in LSR. With two-shot injection molding, thermoplastic material functions as the substrate to accommodate the liquid silicone rubber‘s inherent quality of compression and elongation.

Historically, Thermoplastics (TP) and Liquid Silicone Rubber (LSR) occupied distinctive universes. Although similar in many ways, each method solved an array of challenges by employing different manufacturing processes. Since its introduction into the world of materials science in the 1970s, LSR has become the “go-to” material for product designers and manufacturers across a broad range of industries. The unique properties of LSR — such as stability, non-reactivity and resistance to extreme temperatures — make it the ideal material choice for numerous applications.

However, product designers have the ever-present challenge of creating high-performance products with the fewest parts. In recent years, advances in material technology have given designers the luxury of combining silicone rubber with thermoplastics in a 2-Shot molding process. This method allows manufacturers to produce single-molded components comprising multiple materials with unique performance characteristics.

To execute the project feasibly, we provide a DFM report to review your design and identify any flaws and errors before starting the production process.

We deliver T1 sampling for inspection and review before mass production. The process ensures error identification and precise manufacturing of the plastic part.

Another technique uses a rotating tool that has two molds incorporated into one machine. One mold fabricates the rigid substrate and the other mold applies LSR over-mold material. Upon completion of the thermoplastic substrate, a hydraulic or electro-server drive rotates the core and the part at a 180-degree angle (or 120 degrees in a 3-shot method), which allows for the injection of the alternating materials.

At Kemal, we follow international tolerance standards and rigorous quality control inspection to meet the highest excellence and fulfill your provided specifications.

Count on our on-demand CNC machining services for your parts on time, every time. Achieve outstanding results with our CNC milling and turning capabilities in as fast as five days.

You can obtain consistent results with the use of self-adhesive liquid silicone rubber whether you use a separate mold in two machines or a multi-shot injection mold with a single machine. If you must use two machines in your two-shot molding process, automation will ensure you maintain a consistent temperature for the over-molding and eliminate the possibility of contamination from human handling. Prior to doing a full-production run, a preliminary test should be conducted to give a good understanding of how well your particular substrate will bond to the LSR material you choose.

You must collaborate with an expert who understands LSR two-shot injection molding and the different nuances of working with LSR and thermoplastics as well as the appropriate tooling and processes for each.

The Kemal team has a complete quality control system for incoming raw material, plastic mold manufacturing, injection molding production and delivery.

As the multicomponent injection-molding process relates to liquid silicone rubber, it describes the injecting of a LSR material in the same unit immediately after the molding of the rigid substrate to create a soft-touch feel. This process makes many consumer products more aesthetically appealing, allows for the application of the LSR in the precise position needed, and increases consistency.

The predictive model process analyzes molten material behavior within the mold. The advanced mold flow analysis ensures high-quality and precise molded parts.

Our team securely packages your plastic molded parts before dispatching them to avoid damage. We have partnered with logistics to schedule timely delivery at your place.

Kemal provides prototyping services, including 3D printing, CNC processing, vacuum casting, prototype injection molding, Metal Sheet Fabrication, etc