TECHNOLOGIES & PROCESSES · FUNCTIONAL INTEGRATION

Multi-component injection moulding and hybrid technology

Function. Integration. Precision.

VARIOPLAST is your specialist partner for multi-component injection moulding and 2K injection moulding in Germany. Using state-of-the-art multi-component systems, in-house tool development and fully automated in-line processes, we produce plastic components with integrated functions, reduced assembly steps and the highest level of reproducibility. As an owner-managed manufacturer based in the Enz district of Baden-Württemberg since 1970, we offer you the full spectrum of multi-component injection moulding – from the initial idea through to ready-to-install series production.

Made in Germany – Baden-Württemberg IATF 16949 ISO 9001 ISO 14001:2015 Component weights from 0.01 g to 1,500 g Fully automated in-line production

Enquire now

Discover our services

KEY BENEFITS

Why choose VARIOPLAST for multi-component injection moulding?

Multi-component and two-component injection moulding makes it possible to combine several plastics or colours in a single production step – this reduces assembly processes, improves quality assurance and opens up entirely new design possibilities. VARIOPLAST combines many years of experience, state-of-the-art machinery and highly advanced in-house toolmaking to create a high-performance comprehensive package.

01 – A wide range of processes under one roof

VARIOPLAST covers the entire spectrum: two-component injection moulding, rotary table technology, transfer moulding and core-pull technology. This diversity of processes enables bespoke solutions for components of any complexity and production runs of any size.

02 – Hybrid technology & insert moulding

Camera-assisted robotic gripping technology enables the precise insertion and overmoulding of turned, stamped and bent metal parts – even for the smallest parts weighing as little as 0.01 g. This hybrid technology creates high-strength metal-plastic bonds in a fully automated process.

03 – Two-component injection moulding + Variothermie

In combination with the variable temperature control process, VARIOPLAST achieves the highest surface quality in two-component injection moulding for high-end visible parts. The dynamically temperature-controlled mould surface eliminates weld lines and sink marks.

04 – Fully automated in-line finishing

Following multi-component injection moulding, further finishing steps follow seamlessly: laser marking, PVD metallisation, painting, pad printing or ultrasonic welding – all in-line, all automated, all from a single source.

Range of Services

Our processes in multi-component injection moulding

From the initial concept to the ready-to-install component – VARIOPLAST is your comprehensive one-stop partner throughout the entire value chain. Every stage of the process – from development and toolmaking to assembly and packaging – is carried out in-house and under a single, unified quality management system.

Two-component injection moulding

Two different plastics or colours in a single mould and a single production step
Hard-soft combinations (e.g. PP/TPE) for ergonomic grip elements and sealing functions
Two-colour components without subsequent painting or assembly
Rotary table technology for precise positioning of the first component prior to the second shot
Applications in the automotive, electrical engineering, household appliances and medical technology sectors

Multi-component injection moulding (3+ components)

Integration of three or more materials into a single component
Combination of hard, soft and functional components in a single process step
Reduction in assembly processes through maximum functional integration
Transfer moulding technology and core-pulling techniques for complex geometries

Multi-component injection molding (3+ components)

Hybrid technology & insert moulding

Overmoulding of turned, stamped and bent metal parts
Camera-assisted robotic gripping technology for precise and secure loading
Sheet metal overmoulding for structural metal-plastic composite components
Component weights ranging from 0.01 g to 1,500 g can be processed

Variothermie

Dynamic mould temperature control for surfaces suitable for visible components
Elimination of weld lines, sink marks and visible glass fibres
Suitable for decorative display frames, front panels and automotive control elements

Areas of application

Typical components produced by multi-component injection moulding

Multi-component injection moulding is used wherever functional integration, sophisticated aesthetics and a reduction in assembly steps are required:

Control elements with hard-soft tactile feedback (buttons, handles, rotary knobs)
Two-tone housings and bezels for automotive and consumer electronics
Sealing elements and functional parts with integrated soft components
Metal-plastic composite components (insert moulding, overmoulding)
Light guides and optical components with transparent elements
Display frames and front panels using Black Panel technology
Functionally integrated automotive supplier parts in accordance with IATF 16949
Medical technology components with integrated sealing and grip surfaces

FREQUENTLY ASKED QUESTIONS – FAQ

Frequently asked questions about multi-component injection moulding and hybrid technology

What is the difference between 2K injection moulding and multi-component injection moulding?

In 2K injection moulding, two different materials or colours are combined in a single mould in a single shot. Multi-component injection moulding is the umbrella term for all processes involving two or more components – including 3K and more complex systems. VARIOPLAST has expertise in both variants as well as specialised sub-processes such as turntable and transfer moulding.

Which materials can be combined in two-component injection moulding?

Typical combinations include hard-soft bonds, such as PP with TPE or ABS with TPU. Combinations of two different hard plastics in different colours are also common. The key factor for a durable bond is the chemical compatibility of the two materials. VARIOPLAST can advise you on the optimal material combination right from the development phase.

At what production volume does 2K injection moulding become cost-effective?

Thanks to fully automated in-line processes and extensive use of robots, 2K injection moulding at VARIOPLAST is cost-effective even for medium-sized production runs. The moulding costs are often recouped more quickly than with conventional 1K solutions followed by assembly, thanks to the assembly steps saved and the increased process reliability.

Does VARIOPLAST offer in-house toolmaking services for two-component injection moulding tools?

Yes. VARIOPLAST has its own in-house toolmaking facility at its production site in Baden-Württemberg. Multi-component moulds are designed, manufactured and tested by our team – including design support right from the development phase. In addition, a tool procurement team in Hong Kong is on hand to provide cost-optimised solutions.

Can VARIOPLAST combine 2K injection moulding with surface finishing?

Yes – that is one of the key advantages of VARIOPLAST as a one-stop partner. Following 2K injection moulding, fully automated in-line processes such as PVD metallisation, painting or laser marking are carried out. This results in finished, surface-treated components without any external intermediate steps.

Request a quote now

Would you like to learn more or request a quote right away? Contact us—VARIOPLAST is here to serve you as a reliable partner with over 50 years of experience.

Contact: contact@varioplast.de | www.varioplast.de

Location: Enzkreis, Baden-Württemberg, Germany – Made in Germany since 1970