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.

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.

Our facility utilizes high-precision plastic injection molding and injection mold tool building equipment. In-house injection molding machines range in tonnage from 30-Ton to 250-Ton. Injection molding capabilities range from single cavity, pre-production injection molds to high cavitation molding using a hot runner system. The injection molding equipment used by Medacys is manufactured by some of the most trusted brands in the industry, including Sumitomo (SHI) Demag, Toyo Machinery, and Haitian International.

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.

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

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

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.

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

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

Gilero provides a range of manufacturing services, including plastic injection molding and injection mold tool building. We focus solely on the medical device and drug delivery markets. Our medical injection molding facilities follow strict design protocols and process controls to ensure that all products meet the required specifications. Depending on client needs and product requirements, we can offer manual or fully automated production lines for molding and assembly.

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.

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.

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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.

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.

In comparison to other manufacturing practices, plastic injection molding for medical devices is very flexible and allows for full customization of components. It is used in high volume situations to fulfill injection molded medical device and drug delivery devices with high accuracy and precision. From an operational perspective, plastic injection molded medical devices are produced with low labor costs, are positioned to be scalable as the client grows in sales, and are more environmentally friendly due to the extended life of the product and reduction of waste.

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.

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.

Gilero stands out as an excellent choice for medical device injection molding manufacturing. Medacys, our joint-venture facility in Shenzhen, China, spans 36,000 square feet and is equipped with cutting-edge technology. The skilled team, comprising manufacturing technicians, tooling designers, quality engineers, and engineering project managers, specializes in the medtech and biomedical sectors. This specialization ensures a deep understanding of the unique requirements and regulatory standards in these fields. Gilero offers dedicated areas for various manufacturing processes, including tooling, molding, assembly, and laboratories. We maintain environmentally controlled cleanrooms for precision. Our in-house injection molding machines range from 30-Ton to 250-Ton, and they use equipment from trusted brands like Sumitomo (SHI) Demag, Toyo Machinery, and Haitian International.

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.

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.

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.

The choice of material will depend on the specific requirements of the part being produced, such as its mechanical properties, chemical resistance, and environmental factors like temperature and humidity.

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

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.

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

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.

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.

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

Located in Shenzhen, China, is Medacys – Gilero’s joint venture toolmaking and medical injection molder. This state-of-the-art injection molding facility spans 36,000 square feet and is staffed by manufacturing technicians, tooling designers, quality engineers, and engineering project managers. The expertise of the Medacys team focuses largely on the medtech and biomedical industries. With dedicated tooling, molding, assembly, and lab areas, along with environmentally monitored and controlled cleanrooms, our Shenzhen facility provides plastic injection molding services for companies across the globe.

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.

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.

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.

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

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.

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

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.