A new multiple in-mold decoration process allows injection molding parts with several differently decorated surfaces using just one dual-barrel injection machine.

A new multiple in-mold decoration process allows injection molding parts with several differently decorated surfaces using just one dual-barrel injection machine. The new Duo Lamination process from Georg Kaufmann Formenbau AG., Busslingen, Switzerland, is aimed initially at automotive interior parts, though it also could be used for furniture. The process uses the stationary and moving mold halves to mold the rear sides of the parts and a central rotating cube with four identical cavities to mold the front, decorated sides of the parts. The process also relies on pin- or lug-shaped part contours to achieve mechanical bonding of the decorative materials with the back-molding resin. The pins/lugs also serve as an exact means of positioning the decorative materials in the cavity without wrinkles and creases during back-molding. The bonding technology is being patented by Kaufmann and molder Peguform GmbH of Bootzingen, Germany. The process requires an injection machine with a rotary table mounted on a carriage, as well as a second injection unit. The part is produced in four stages. The basic decorative material is inserted from one side of the machine into the cavity of the cube-shaped block and turned by the rotary table 90 ° so that the reverse side of the decorative material in the cavity faces the stationary mold half, where the part is then partially molded with the fi rst material or color. This intermediate part is rotated another 90 °, where the pre-cut decorative materials are inserted into the cavity and located with pins or lugs integrally molded in the previous stage. The table rotates the part another 90 ° to a position opposite the moving platen, where it is back-molded by the second injection unit. The table turns the last 90 ° for part demolding. Tel: +41 56 485 65 00 . www.gktool.ch