INDUSTRY FOCUS Automotive Supply Chainy
Benefi ting from ‘multi’ trends
Multi-component moulding is currently undergoing a surge in popularity as it evolves in new directions, confirms Nigel Flowers, Managing Director of Sumitomo (SHI) Demag
T
ransparency Market Research states in a recent report that the global market for multi- component moulding will reach
$11.58bn by 2024. The automotive industry commands the lion’s share of this market, with approximately 30% of European demand for multi-component parts. This sector looks set to remain strong, driven by advancements in touchscreen electronics and the advent of sophisticated multi-face tooling that allows for in-mould fi nishing and assembly. The trend here is towards producing a single component that would have historically required several separately- moulded parts and off -mould processes. For example, by combining multi- component moulding with touchscreen technology, a car dashboard can be moulded as a single element with the HMI functionalities sandwiched between the plastic. As well as looking smart, this reduces the cost of production by eliminating the need for laser cutting, etching, and so on.
Another example of a growing automotive application is the production of the bezels that surround satellite navigation systems. The electronic touchpad for the satnav is laid inside the mould, then trimmed and tested, ready to go into the vehicle. At present, it is the automotive parts that account for the majority of applications; however, other sectors, such as medical devices, consumer goods, packaging and electronics, are expected to experience the biggest growth in multi- component moulding over the next fi ve years or so.
24 October 2020 | Automation
Aesthetic appeal and functionality In FMCG manufacturing, multi-component moulding appeals to companies seeking innovative and creative ways to integrate multiple colours, resins and sensory features into products, in order to provide diff erentiation. Combinations of materials, such as silicones and thermoplastics, PP and opaque thermoplastics like ABS, or hard plastics with a soft-touch material, are especially popular in the personal care market. Some of the most common examples include disposable razors, toothbrushes and bottle caps. But, as sustainability climbes the corporate agenda, interest has shifted away from multi-material moulding and towards multi-colour moulding, as this enables the production of fully-recyclable mono-material components. Some brands in the premium space have adopted this approach.
In the medical device segment, the driver behind multi-component moulding is creating precision-moulded products with specifi c physical properties and functionalities. Adding a sealing solution, for example diaphragms, O-rings, gaskets and lip seals, to a medical component is critical to ensure resistance to potentially harmful and toxic chemicals and prevent cross-contamination risks.
Filling a gap
Sandwiching applications that go beyond burying low-cost scrap material within a part are another major growth area. From a circular economy standpoint, sandwich- moulding off ers options to integrate recycled materials for the inner part of the component. Examples include the trays
used for protecting kitchen appliances during transit or for transporting automotive parts around a factory, with a fi lling from lower-value recycled material. As rising demand for recycled materials closes the price diff erential with virgin materials, moulders are looking to other ways of fi lling the cavity. The use of gas injection to hollow out the centre of the product, for example, makes it easier to recycle, plus there is the cost benefi t that comes from a reduction in weight, material usage and cycle time.
Pros and cons Injection moulders are realising how much they can save by producing a fi nished part in the mould without the use of downstream equipment that takes up fl oor space and is expensive to buy, operate and maintain. In its most basic form, multi-component moulding removes the assembly stage, whether clipping or gluing, reducing assembly costs by up to 20%. The fact moulding takes place within one cycle also means it is more productive than conventional moulding – total manufacturing cycle time may be trimmed by up to 20% due to reduced handling of the part.
However, there are downsides to multi-component manufacturing. Capital investment is higher than with a standard press. This is partly because many multi- component or co-injection presses are customised, making them more expensive, but also because tooling costs are higher due to the complexity; it is more diffi cult to repurpose the mould for diff erent products than it is with a standard injection moulding process. In addition,
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