Injection molding is known for its speed, repeatability, and ability to produce complex geometries efficiently. Parts have tight tolerances and low scrap rates. Although injection molds have high initial costs, injection molding has a low per-part cost at high volumes, making it ideal for mass production.

Overmolding is ideal for cost-effectively combining the benefits of disparate materials into one part with enhanced functionality. It simplifies assembly and improves reliability.

You will experience fast and direct communication which ultimately leads to a seamless and smooth manufacturing process.

We ensure to only use imported and certified steel as well as the standard components you prefer to build your molds. This guarantees us to manufacture medical device molds of the optimum quality that medical device manufacturers should adhere to.

Standardization and quality are part of our companies core values. We deliver the best possible experience and product to our customers, every single time consistent. Take a look at our certificates!

Two-shot molding provides unique advantages but requires more investment and process expertise than conventional single-shot injection molding.

In this process, two separate plastic materials are injected sequentially into the same mold cavity. The first shot forms the core part; the second shot molds a second material onto the core. The two materials bond through thermal and molecular diffusion, creating a two-material or two-color component with unique properties.

Initial investment: Multi-shot requires the highest investment in equipment and tooling. Two-shot and overmolding have lower startup costs.

Two-shot injection molding, also known as 2K molding or two-color injection molding, is a plastic molding process that combines two different plastic materials into a single part.

Injection molding is a typical manufacturing process for producing plastic parts in high volumes. The primary plastic injection molding process involves melting plastic material into liquid and injecting it under high pressure into a mold cavity. The plastic cools and solidifies inside the mold, taking the shape of the mold cavity.

To keep the two melts separate, the two-shot molding requires specialized injection molding machines and molds with two separate barrel and nozzle systems. It combines the advantages of two plastics, such as flexible and rigid polymers, into one part.

Two-shot and overmolding combine two materials using sequential molding, while multi-shot allows complex combinations of three or more materials through multiple injections into one mold. Overmolding also differs by using a pre-formed substrate part. All provide unique part consolidation and property integration, but multi-shot is the most complex process.

We also help in establishing an entire assembly along with testing procedures. All the procedures that are established are optimized to deliver the best, in terms of quality and an efficient turnaround time.

Multi-shot injection molding involves injecting two or more different plastic materials sequentially into a single mold cavity to produce complex, multi-material plastic parts in one shot.

Plastic injection molding produces plastic parts by injecting molten plastic into a mold cavity. In two-shot molding, two different plastics are injected in sequence into one mold to create a two-material or two-color part. Multi-shot molding injects three or more plastic shots into a single mold to create parts with multiple materials or colors. Overmolding involves injecting one material onto a pre-molded part already placed in the mold, combining two materials into one part. Multi-shot and overmolding combine different properties like flexibility, strength, and texture into one part. They increase design freedom but require more complex tooling than standard injection molding.

Production volumes: Two-shot is better for medium-high volumes. Overmolding is better for low-volume production or plastic prototyping. Multi-shot is only viable for high volumes to amortize tooling.

Some examples of over-molded parts include toothbrushes with soft grips, rubber seals molded onto metal components, and handles molded onto tools. The substrate can be plastic, metal, wood, or pre-assembled sub-components.

In a multi-shot process, the mold has multiple nozzles injected into the same cavity at different times. The first shot of molten plastic is injected and allowed to partially or fully harden. Next, a second shot of a different material is injected against the first, followed by more injections as needed.

The process starts with the first material being molded to create the core component. It is known as the substrate or substrate part.

Delivering all facets of medical device manufacturing from medical device plastic injection molding to assembly and packaging in a Class 10,000/ISO7 Clean room environment.

VEM Tooling continually invests into engineering resources thus, we have the expertise, skill-set and technical knowledge to assist you with your medical device manufacturing across various stages and complexity levels.

Overmolding provides unique advantages but requires material selection, mold design, and process optimization expertise.

VEM Tooling also ensures to deliver spare parts and the replacement parts of the medical device molds at the lowest lead time. Additionally we can guarantee the quality of the replacement or the spare parts is as per the quality standard.

Overmolding is a plastic molding process where one material is molded onto a second pre-formed material. It combines two different components into a single part.

Throughout the process, we follow standard protocols and keep continuous improvement efforts to the highest level. This allows us to remain highly competitive in terms of quality and lead time.

The process starts by feeding small plastic feedstocks into a hopper that feeds the injection molding machine. The pellets are melted inside a heating barrel using heaters and rotating screws. Once molten, the plastic is injected through a nozzle into the mold cavity with a clamping unit keeping the mold closed under pressure.

Our manufacturing experience and input during an early product design phase has helped our clients to save upon resources and time. By partnering early during the product design phase development, we have eliminated common errors and mitigated redesign issues that may arise due to complexities thus, we encourage medical device manufacturers to partner with us during the product design phase stage.

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The two materials bond together to create the final over-molded part. The substrate provides the core strength while the overmold provides a gripping surface, seal, gasket, or adds aesthetic appeal.

Inside the mold, channels cut into the mold allow coolant to circulate and solidify the plastic. Once cooled, the mold opens, and the finished plastic part is ejected. The mold then closes, and the cycle repeats.

At VEM Tooling, we focus on providing precision, accuracy and quality for our medical device manufacturers. We are one of the few medical device injection molding companies that provides the entire supply chain with manufacturing capacity in cleanrooms and whiterooms.

This also ensures better lead time and enables us to incorporate any type of minor or easy modification that the mold may require.

Part complexity: Multi-shot can make the most complex multi-material parts. Overmolding is limited if the substrate is complex.

The Class 10,000 Clean Room includes injection machines for medical devices, assembly and subassembly units and machines as well as final packaging facilities. The cleanroom is equipped with the latest technology such as QC equipment and robots to ensure smooth mass production capacity. Along with the production facility, we also develop validation protocols, testing procedures and process improvement studies to ensure highest quality and competitiveness.

To better understand how VEM Group serves the medical device manufacturing industry contact us or request a quote today. We are looking forward to becoming your trusted medical device injection molding partner.

Overmolding allows the combining different properties, like rigid and flexible polymers, into one part. It eliminates the assembly of separate components with fasteners or adhesives.

Medical device manufacturing requires that every device and equipment is manufactured according to the standardized quality and without any compromise to the safety. Thus, Medical Device Injection Molding should always be carried out in ISO certified cleanrooms or whiterooms. This ensures that medical devices are protected from all types of dust, aerosol particles, airborne microbes and chemical vapors or any other contaminants at every development stage.

Multi-shot molding requires specialized machines with additional injection units and complicated hot runner systems to deliver the separate melts. Each material must be compatible with the other and have proper bonding characteristics.

The multi-shot process allows the combining three or more plastic materials into one part. It provides design flexibility to integrate different properties, colors, finishes, and functions into one component. Multi-material parts can integrate soft touch grips, seals, gaskets, hinges, and clear window lenses into a single molded part.

The number of materials: Two-shot combines 2 materials, multi-shot can combine 3+ materials, and overmolding usually just 2 materials.

The substrate is then loaded into a second mold cavity where the second material is injection molded to form an outer layer around the substrate. It is known as overmolding.

All the equipment in the clean room at VEM is equipped to be highly automated with robotics. This aids our engineering and manufacturing team to reduce production errors. It also optimizes the manufacturing cycle thus, boosting productivity.

We support medical device companies with an end to end solution by carrying out their entire supply chain. This ranges from improving product design for manufacturing purposes & engineering to molding, product assembly, and its packaging.

VEM Tooling’s Thailand Plant is ISO 13485 certified and has an ISO 7/Class 10,000 cleanroom after ISO 14644-1:2015 certification. Our mold design, engineering and manufacturing team follows rigorous standards to make medical device molds.

Benefits of two-shot molding include design flexibility, consolidated part assembly, cost-effectiveness, and achieving a combination of characteristics like soft-touch grips or rubber seals bonded to rigid plastic. Two-shot molding is ideal for complex products with decorative effects like control panels, automotive trim, medical devices, and consumer goods.

At VEM Tooling, we build medical device molds in our factory units due to which we have complete control over quality. To design and build the mold, we either follow customer standards or use our VEM standard design.

VEM Tooling is committed to providing our clients with the best medical device manufacturing service. At VEM, we also ensure that you receive clear and timely communication. These are the core values at VEM.

Tooling cost: Multi-shot molds are the most expensive. Over molds need two tool sets, and two-shot tools fall in between.

Multi-shot molding consolidates assembly processes, reduces labor, and improves durability over multi-part assemblies. It is ideal for complex products like auto interior trim, consumer electronics, medical devices, and industrial parts. However, the molds and equipment are complex, requiring significant expertise.

Multi-shot molding can produce innovative multi-material parts but requires very complex processing and high initial costs compared to standard injection molding. Pros:

VEM’s Medical & Healthcare Tooling Factory encompasses an extensive industry experience in the medical device manufacturing industry. We understand the manufacturing standards that need to be followed which is why we ensure to adhere to the ISO 13485 production standards.