What are 2K Injection Molding and 2K Molding Equipment ... - 2k molding
Author:gly Date: 2024-10-15
Support for the very highest standards and technical requirements. For example, we support ISO8 cleanroom injection molding.
The Kemal team has a complete quality control system for incoming raw material, plastic mold manufacturing, injection molding production and delivery.
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.
Our manufacturing process adheres to a stringent quality control system that guarantees exceptional prototypes and production parts.
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.
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.
Also known as polyethene, polyethylene is the most commonly found plastic around the globe, with annual production being around 80 million tonnes.
J-CAD has a long-standing positive experience of close to a decade in foam injection molding. All of our products are of superior quality. Our experience coupled with recent technological improvements has enabled us to develop our own advanced structural foam injection molding system that produces products of ultra high quality.
Kemal provides prototyping services, including 3D printing, CNC processing, vacuum casting, prototype injection molding, Metal Sheet Fabrication, etc
Kemal offers proficient technical assistance round the clock, backed by a proficient team of skilled engineers and technicians.
EVA foam is non-toxic and easy to work with. It has some of the properties of a low-density polyethylene with increased gloss, softness and flexibility. It’s also weather resilient; with resistance to UV radiation, low temperatures, good impermeability and high stress-crack resistance. There are both filled and unfilled EVA products. Keep reading
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.
High-Quality Dimensioning With EVA Foam molding the process can be closely controlled, so you can expect to produce really consistent dimensional parts. The manufacturing of the foam and the final product are the same, they happen at the same time. Because of the simple controlling of the process, there is minimal part-to-part variation.
The process starts with the gas/polymer mixture being short-shot injected through nozzles directly into the mold. The blowing agent then expands and pushes the molten resin into the cavities, thus reducing sink holes over heavy cross-sections. This approach to manufacturing gives the product a cellular core surrounded by a rigid and dense outer skin, building structurally sound products while reducing their weight and density because of the development of the structural core. Keep reading
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.
Polyurethane foams are made by mixing two-part polyurethanes, that expand upon mixing and fill the molds, allowing for a lot of variety in material density and functionality. It’s important to stabilize both polyurethanes to a certain temperature; if when mixing the temperature is too hot the foam will be too light and weak, if the temperature is too cold the foam becomes too dense.
We use preferred material for mold tooling production to provide premium-quality and tailored mold tooling that perfectly fits your application’s specifications.
Learn how Kemal manage the whole manufacturing process of Injection Mold and complete your order on budget and on time, batch after batch.
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.
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.
Aesthetically Pleasing EVA Foam develops a perfect mold finish upon completion, the process creates parts with great aesthetics, and the quality is always consistent. And even though EVA Foam products are more expensive than other types of foam production, the result is always an attractive product with long-lasting value which is less likely to deteriorate over time.
Thickness variation EVA Foam injection molded parts can be made to any height or width, they aren’t limited by the process. There’s no need for lamination.
Direct injection expanded foam molding is also known as injection molded foam, and it’s used to create soft foam products from a complex base resin made from an ethylene and polyolefin elastomer. They become very rigid, but are really easy to use and cure, and can be used as a lightweight casting or filling material.
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.
Polystyrene is a synthetic compound, that can be solid or foamed. It is made from monomer styrene and is considered and aromatic polymer. It is one of the best materials that could possibly be used for foam injection molding.
The foam made from it is closed-cell and waterproof, its cells are tightly connected, giving the CFAs are typically used when trying to achieve higher density foams and they can improve the quality of the final product immensely. They are often used for the production of strong, yet lightweight structural foam moldings. As well as the extra strength, — depending on the shape of the mold – CFAs will also save you money, since thicker walls make it easier for the foam to form. You can generally expect a reduction of 10 to 25% of the weight, or even more with a well-formed design.
You can add CFAs to the injection molding machine just as if they were colorants or additives. CFAs can also allow for an increase in shot speeds and can reduce clamp tonnage, achieving a reduction that can be as high as 30% in cycle and production times. Pretty amazing benefits from using just one simple additive!
We deliver T1 sampling for inspection and review before mass production. The process ensures error identification and precise manufacturing of the plastic part.
When working with lower pressure, there’s the benefit of being able to use more economical molding equipment, for this reason, it is cheaper to do mass production of larger, thicker parts by structural molding, than conventional injection molding. And you can expect the finished part to be typically 10 to 30% under the weight of an equivalent conventional injection molded part.
There are many kinds of CFAs, since they can be organic or inorganic compounds. CFAs generate exothermic or endothermic reactions, and they are used in this process to nucleate the foam structure that results from the expansion of the gas that is injected to the mold, as it decomposes while dispersing through the polymer melt. Keep reading
The predictive model process analyzes molten material behavior within the mold. The advanced mold flow analysis ensures high-quality and precise molded parts.
Working with our experts having 20+ years of experience in the injection molding industry, efficiently complete a turnaround from prototyping to production.
Flexible polyurethane foams are easy to use and durable, and very efficient for absorbing energy at controlled rates, changing resonance or shock-pulse frequencies and relieving static stress on flexible materials. Some foams are also great at handling really high temperatures, with some avoiding long-term effects up to 180°F.
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.
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.
After the trial phase, we provide low-volume production service to ensure precision with efficient machinery under expert surveillance, saving time and cost.
At J-CAD Inc. we produce a very wide variety of products owing to our diverse customer backgrounds and industries served. Our products include:
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.
In Foam injection molding, thermoplastic materials are first melted. When the melted plastic is evenly soft, an inert gas (blowing agent) is introduced into the polymer melt to make the solution foam-able. The solution is then injected into a mold to make the foam product.
EVA, or ethylene-vinyl acetate foam is a soft and durable polymer processed as a thermoplastic material, commonly used in flooring and sports equipment due to it being highly cushioning and sponge-like.
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.
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.
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.
If you don’t feel foam is right for your product (ask us to clarify if you’re not sure) we also have much experience in silicone and plastic injection molding.
can work well as long as they are sealed and a silicone release agent is used on them prior to molding. Another plus with molding in flexible foam is the ability to add color pigments to achieve vibrant colors.
Post Mold Stability Injection molding gives EVA Foam parts a very soft and malleable body after finishing their molding cycle. Because of this malleability a cooling fixture is sometimes required during the post-molding phase.
One interesting fact about flexible foam is that it contours around molds, allowing you to take shapes and make flexible objects that can easily be used for production items. These are usually produced with silicone molds, but urethane or other molds Keep reading
Low-pressure structural foam molding is very similar to the conventional injection molding process, with a much lower pressure. In most instances of low pressure molding, the molten polymer is injected with nitrogen gas, a chemical blowing agent or an inert gas (NI, CO2, CBA…). The mold won’t be completely filled with the resin as with high-pressure molding, the injected gases are mixed with the polymer, and then they are allowed to expand inside the mold.
Polyurethane is a polymer that is available in thermosetting (does not melt when heated) and thermoplastic (melts when heated) versions.
If you have any question just get in touch with us! At J-CAD Inc. we’ll be glad to help you with your project. Call us 1-888-202-2052 or email jason@jcadusa.com
If you haven’t noticed, it is highly unlikely that a day comes by without you seeing some sort of polymer foam, they are being used everywhere with an incredible array of applications. You may ask yourself why are they everywhere?
Structural molding shares some similarities with injection molding, but these are the main differences between the two processes:
At Kemal, we follow international tolerance standards and rigorous quality control inspection to meet the highest excellence and fulfill your provided specifications.
Our equipment have been customized to ensure utmost efficiency and cost effectiveness while maintaining superior quality. Our pumps can handle a highly controlled flow rate of a very wide range. They also handle a wide pressure range that is highly regulated.
At J-CAD Inc. we are not specific about the form in which you provide us information about your project design. It could even be hand drawn, we don’t mind. We will convert it to a 3D file required for mold making and injection molding mass production. We will work with you to ensure that the design is optimized for the purpose for which it is intended. Our experienced team of highly skilled designers will help you bring out the best out of your product.
Kemal takes responsibility for the quality of each mold. That extends as far as signing a mold quality warranty with customers for each tool.
The foam made from it is closed-cell and waterproof, its cells are tightly connected, giving the foam a high tensile strength and making it strong and durable.The main benefit of injection molded foam is that its cycle is way faster; the foam and product are both manufactured simultaneously, as this process doesn’t require die-cutting or compression molding. Also, given its really high expansion rate, the products manufactured are self-skinning, meaning that they have a great reproduction of surface detail.
The visual above is just the basic principle of the foam injection molding process. The quality of the end product is highly dependent on how delicately the foam injection process is balanced which we have mastered at J-CAD Inc. We have done away with stop-and-flow molding because of the resulting inconsistency in gas dosing. We have come up with ways to ensure that there is continuous flow of both the blowing agent and polymer during the injection process. We have also introduced a lot more modifications to ensure that the end products are of superior quality and the cost of our products are affordable.
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.
One important feature of CFAs is their ability to be processed on all injection molding machines, if you know what you are doing. In order to obtain a uniform foam structure, the CFAs injection rate requires special attention.
When doing foam injection molding there are several ways of modifying a material’s properties. In most instances what you are looking for is weight reduction and sink removal on your parts, and one of the main ways of solving that is the usage of Chemical Foaming Agents (CFAs).
This type of resin can also be colored with a variety of additives and is very resistant to most chemicals. This allows products to be suitable for lots of uses. Keep reading