More OEMs are relying on complex injection molding—an advanced process that requires highly-specialized equipment, operator skills, and engineering expertise—to manufacture products that require multiple materials and higher tolerances. Complex molding allows companies to create more advanced products, while reducing assembly time and speeding up production—which translates into higher quality, lower costs, and satisfied clients.
Selecting the proper materials for a complex molding project requires a deep knowledge of material science. Kaysun maintains a vast in-house database built over 60 years of experience that documents how polymers, metals, and other nonplastics react to different molding conditions. Material compatibility is absolutely essential to ensure a permanent chemical bond.
The mold or tool is then designed and built by the engineering team, according to the materials selected and the quantity of the item to be produced. One of the most common complex injection molding techniques is multishot technology, which is required to add softer polymers for ergonomic and waterproofing features (such as keypads, grips, protective bumpers, and seals) over a hard-plastic substrate, such as an impact-resistant device body.
Process controls monitor materials during production through cavity pressure feedback—a pressure reading of the resin as it is going into the mold. The feedback provides data on the consistency of the pressure and where correction (if needed) should be applied. Compared to standard molding procedures, complex injection molding results in higher quality because consistency and tight tolerances can be precisely maintained, regardless of how many units are produced.
