Combining productions steps with intelligent mold technology
Ultrasonic welding of individual parts formed beforehand by injection
molding is a widely used process for the production of hollow parts
with functional interiors. However, the disadvantage of employing two
processes — each requiring their own monitoring — is often compounded
by quality issues, especially when multi-cavity molds are used. The
assembly elements usually come from different cavities and may present
slight form variations leading to higher scrap rates during the welding
process. Usually this problem can only be overcome only at great cost
by using automation technologies to ensure a uniform part assembly.
Joining elements inside the mold
Ferromatik’s unique overmolding assembly process can help here. Through
intelligent mold technology assembly can be re-located into the mold.
With single-stage overmolding, the assembly elements, as well as the
joining, are completed within one cycle. In this case the assembly
elements are produced in the previous cycle and are brought together
while still held (figure 1) by index platen, for example. With
the two-staged process the assembly elements and the joint are produced
alternately on the finished product (figure 2). The combination of
these two processes within the injection molding process – means a
reduction of costs and greater productivity. The overmolding assembly
process is also available with
multi-component technology. In this case the assembly elements or the joint can be made from different components or colors.
A Solid Foundation
Overmolding assembly technology can be implemented on all of our
machines, combining the unique advantages of each machine series with
the benefits of this unique process. For example,
MAXIMA machines can used for the production large parts for
auto industry. The
ELEKTRA
series is not only eco-friendly and energy saving – it also brings the
benefit of exceptional precision to overmolding assembly. In many
cases, parts made with the this process require a high performance
machine such as the MAXIMA
topline- or any of the
K-TEC series.
