Secondary Injection Moulding: Multi-dimensional Processing Technology for Medical Devices

Secondary injection moulding can not only make the surface of instruments soft, but also increase product functionality and added value.

In the past 10 years, secondary injection technology has thoroughly changed consumer aesthetic standards, design concepts and functional requirements. Medical device manufacturers have also recognized the potential advantages of this technology and continue to expand its application in the medical field. Thesecondary injection mouldingtechnology is known for creating "soft surfaces", but it also has many other functions, such as ergonomic design, two-color appearance, brand logo, and feature improvement. Using this technology, product functionality (such as noise reduction, shock absorption, waterproofing, and collision prevention) and added value can be increased.

Secondary injection moulding, like co-injection moulding, two-color injection moulding, and sandwich injection moulding, belongs to multi-material injection moulding technology. The basic idea of multi-material injection moulding is to combine 2 or more different materials with different properties to improve product value. In this article, the first injected material is called the substrate or base material, and the second injected material is called the cover material.

Various secondary injection moulding  technologies

During the secondary injection moulding process, the cover material is injected above, below, around or inside the substrate, combining to form a complete part. This process can be completed through multiple injections or embedded injections. The cover material commonly used is elastic resin.

However, multiple injections are not suitable for all products. During secondary injection moulding, the slide must be moved or the mold core must be moved to another mold cavity. Another method is to send the mold core to another injection moulding machine.

Molded in assembly of injection moulding

Secondary injection moulding is sometimes called in-mold assembly because the two materials are completely combined at the end, rather than just producing a layered structure. This technology can be used for both individual parts or component materials. It is critical to ensure that the substrate and cover materials achieve the required mechanical or chemical bonding strength, regardless of the application.

Cautions for multi-material injection moulding

Generally speaking, if you want to strengthen adhesion, the melting temperature of the cover material resin should be the same as that of the substrate. If the melting temperature of the cover material is too low, the substrate surface cannot be melted, and the bonding between the two is not strong enough. However, if the melting temperature is too high, the substrate will soften and deform. When severe, the cover material can penetrate the substrate, resulting in component processing failure. Therefore, selecting matching materials can ensure good bonding. Generally speaking, the matching materials should have similar chemical properties or

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