Using Finite Element Analysis (FEA) in seal design Finite Element Analysis (FEA) is a computerised modelling method for predicting how an object reacts to forces, whether directly applied or generated by pressure, temperature effects or vibration. FEA provides data to help predict how a product will function under those applied conditions. Additionally, it identifies areas where … Continued
Why use 2-shot moulding? 2-Shot moulding is a manufacturing process that allows the co-polymerisation of hard (or soft) plastics and thermoplastic elastomers (TPE’s). We use the 2-Shot manufacturing approach to deliver engineered parts that perform a critical sealing function. What is 2-shot moulding? A 2-Shot mould is designed with a top and bottom cavity. During … Continued
2-Shot moulding is a manufacturing process that allows the co-polymerisation of hard (or soft) plastics and thermoplastic elastomers (TPE’s). We use the 2-Shot manufacturing approach to deliver engineered parts that perform a critical sealing function.
A 2-Shot mould is designed with a top and bottom cavity. During the moulding process the first material is injected into the top cavity and the mould opens and rotates. The first material is then injected into the top cavity again, while the second material is injected into the bottom cavity simultaneously. The mould then opens, and the parts are ejected from the bottom cavity. The mould rotates again and the whole process is repeated.
2-Shot moulding is not considered a brand-new method of manufacturing. Actually, it has been used for years to produce items that we see and use every day. For example, toothbrushes, tools, kitchen utensils and toys are produced by multi-shot moulding. These are relatively cheap items in large production quantities.
Previously, manufacturers of high volume metal or plastic- to- rubber component assemblies have processed them via chemical or mechanical bonding. This was by using adhesives or over-moulding. Markets that lend themselves to these types of sealing products are Automotive, Life Sciences and Aerospace & Defence.
Although these production methods may achieve the final assembly requirement, the many different processes involved are lengthy, costly, and can be fraught with problem areas that require stringent controls. A failure in any of these areas will result in poor quality parts, therefore often deeming these methods unsuitable for critically engineered components.
When designing a new 2-shot moulded product (or replacing an existing assembly part) our engineers review each application parameter carefully. They utilise years of sealing experience and materials expertise alongside the latest 3D modelling technologies. This is accompanied with FEA simulation programs -all before presenting a seal proposal. This allows us to anticipate and analyse the finest details of mould performance and means we can adjust our seal design if required. This is to ensure our customers receive the highest level of performance possible from our engineered 2-shot seal solution.
The result means we supply our customers with high integrity parts with a powerful molecular bond. Additional benefits include reduced production cycle times (because additional processes are removed from the production line) and comprehensive cost reductions. This is because all parts are produced in a single manufacturing tool (meaning reduced running costs and the removal of pre and post moulding processes).
2-Shot moulding is not just a way of manufacturing simple, high volume parts. Our application engineers are constantly breaking norms and pushing design limits. We are proud to consider more creative ways of producing high performance engineered sealing solutions to meet our customer requirements.
Read more about our 2 shot mouldings HERE