Boucherie has introduced Flexi-Cube, a multi-component injection mold that was first used by a customer to produce a three-component handle in a 24-cavity layout.
This five-station mold consists of 24 cavities for injection of the first material, cooling, 24 cavities for injection of the second component and 24 cavities for injection of the third component. The fifth station is outside the mold for product ejection or removal during an active molding cycle. Although the handle features a relatively big wall thickness, the mold can achieve an overall cycle time of 15 sec., the company says.
The core of the mold features a stack design with a central, stationary cube encircled by a solid track on which holders with molded parts travel. Various stations are positioned around the circumference of the cube and linked by a transport system that travels around it. The number of stations and their individual positions and functions can be selected as needed for mold layout flexibility.
Mold versions for four or more components can be built with or without intermediate cooling stations between injection stations, or with one or more ejection stations or positions where premade structures can be insert-molded. Two-component molds also can be designed with maximum cavitation in stack configuration or combined with other functions.