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The classical plastic injection method is based on the principle of injecting a single color of a single polymeric material into the mold cavity under high pressure. In cases where the products are expected to have contrasted functional features and different colors, the classic injection process and the conventional injection molds are not sufficient. This paper proposes a new design approach for multi-component injection molds required by products containing different polymeric materials or different colors of the same polymeric material at the same time. It also presents a case study including the design of the hot runner, electromechanical rotary-cross, cooling, and ejection systems of a two-component, eight-cavity toothbrush mold. The polymeric materials are polypropylene for the first component, and styrene based thermoplastic elastomer for the second component, which exhibit good bonding properties with each other. In addition, an analysis study covering the filling parameters and production defect generations is also provided. The adopted design approach provides a production rate of 1600 parts per hour, corresponding to 18 s cycle time and 200 cycles per hour, and makes it sufficient to rotate only the 80 kg core plate instead of 1120 kg entire core side. Compared to existing methods, the results show that the proposed multi-component injection mold design method eliminates the need for particular injection machines and robotic systems, shortens the cycle time, and reduces energy consumption. [ABSTRACT FROM AUTHOR]

One of the many methods used in the production of plastic materials is plastic injection method. The plastic injection method needs equipment difficult to choose, and it is also costly. Many negativities could be experienced during production. One of them is the water droplet problems on the surfaces of the mold. Provision of insufficient cooling on molds, ambient temperature, non-homogenous humidity, mechanical and other stresses occurring during production, cracks on the product, warpage and thermal residual all cause some stress-like defects. In this study, the effect of water droplets problem on production efficiency in the molds of Polyethylene Terephthalate (PET) raw materials manufactured in a private enterprise was examined. The percentage productivity table has been created based on different months of the year, August July and August. In the enterprise, 8 dehumidifiers were placed to 17 injection machines to create a homogeneous production temperature in the environment. Humidity and heat values obtained during production were monitored daily and recorded. In this study, which was conducted over two years and three months, positive results were obtained suggesting that the water droplets formed in injection molds has decreased with the effect of dehumidification devices, and the efficiency of injection production has also increased by 8%. [ABSTRACT FROM AUTHOR]