The requirements on modern plastic components are constantly increasing. Solutions that are lighter, more functional, and economically manufacturable – without compromising on quality and durability – are in demand. In high profile industries such as medical technology, ophthalmic, or electronics, tight tolerances, versatile material properties, and reliable processes are crucial.
This is precisely where two-shot injection molding comes into play: it combines different materials in a single component, thereby opening up new possibilities in design and production. Frey & Winkler has been supporting this process for many years – as an experienced partner for highly precise multi-component parts.
The two-shot injection moulding process combines two different materials in a single automated cycle that can also include colouring. This results in highly functional components with specifically combined properties – such as hardness and elasticity, transparency and strength, or media resistance and flexibility.
Common use-cases include silicone with thermoplastic, silicone metal combinations, or silicone components made from different Shore hardnesses.
Hard-soft combinations with TPE are also among the frequently used material pairings. The materials are injected sequentially or simultaneously into a specially designed mould and subsequently form a permanent bond – mechanically, chemically, or thermally anchored. Compared to the single-component process, two-shot injection moulding reduces the risk of assembly errors – a crucial advantage in complex components.
Multi-component injection moulding often replaces mechanical joining, adhesive processes, or screwed connection techniques. Instead of laboriously assembling individual parts, a fully integrated component is manufactured in a single production run.
This not only saves time and costs but also improves quality. The material-bonded connection of two materials ensures tightness, minimises tolerance deviations, and increases structural integrity. Moreover, it opens up design possibilities that would not be achievable with conventional methods – for example, ergonomically shaped grip areas, multi-coloured surfaces, or complex geometries.
Frey & Winkler has a modern manufacturing infrastructure specifically tailored to the challenges of multi-component injection moulding. Silicone injection moulding machines with clamping forces of up to 150 tonnes and thermoplastic systems with up to 300 tonnes are used.
The technologies employed – from cold- to hot-runner systems – enable a broad range of applications. With shot weights from 0.5 to 120 g for silicone and 0.5 to 500 g for thermoplastics, we cover both micro parts and medium-sized component dimensions.
Whether demoulded manually or fully automatically, with cavity separation and inline quality control – the processes are designed to implement both series and small-batch production in an economical and reproducable way.
In multi-component injection moulding, the quality of the tool determines the accuracy of the final product. Specialised mould inserts, precisely guided slider mechanisms, and precisely matched gate positions are prerequisites for ensuring that both materials are combined in a controlled manner – without burrs, misalignment, or mould defects.
Frey & Winkler designs and manufactures most of the tools in-house – from initial design to series production readiness. Full integration of toolmaking ensures short design cycles, rapid modification capabilities, and close coordination with series production.
Not every combination adheres easily. Especially with critical materials such as silicone with metal or certain thermoplastics, additional process steps are required to ensure a stable bond.
To guarantee a permanent connection even with difficult material combinations, Frey & Winkler relies on proven pre-treatment processes. These targeted measures significantly improve adhesion, which is particularly crucial in safety-relevant applications where maximum strength, absolute tightness, and long-term stability are required.
The possible applications of two-shot injection moulding are as varied as the requirements of modern industrial products. Whether precision components for medical technology, visually sophisticated design products in eyewear, or functional elements in device construction – the process enables the combination of various sophisticated material properties in a single component.
In medical technology, precision and hygiene are essential. Sealing lips, flexible operating elements, or transparent windows can be seamlessly combined with stable carrier elements through 2c injection moulding. This reduces assembly effort but furthermore also minimises the risk of leaks – a crucial factor for ports, diagnostic systems, or infusion units. Production is carried out in a cleanroom if required and always in compliance with ISO 13485.
In mechanical and plant engineering, multi-component injection moulding enables the integration of multiple functions into a single component – such as sealing, grip zones, and housing structure. This reduces the number of parts, decreases susceptibility to errors, and increases assembly efficiency. Eliminating additional joining processes saves time and material – without compromising functional safety.
Components in the eyewear industry benefit from material combinations that impress both visually and functionally. Hard frames with soft contact zones, colour accents, or translucent elements are easily achievable – with precise repeatability and a pleasant feel. The symbiosis of purpose, comfort, and design makes 2k injection moulding a powerful solution in ophthalmics.
The process is also ideally suited to micro-technology. Shot weights starting from 0.5 grams enable highly precise multi-component solutions for sensor technology, laboratory equipment, or disposable medical products. Thanks to automated processes and tightly toleranced tool design, we produce reliable components – even in high volumes.
Trust is built through traceable quality. Frey & Winkler operates according to the standards of DIN EN ISO 9001 and DIN EN ISO 13485, thereby fulfilling critical requirements for documentation, traceability, and product safety in regulated markets.
In addition to series production, we offer comprehensive support in development and design, validation, and sampling. This ensures that we manufacture solutions convincing from a product perspective and on top are also produced in compliance with regulatory requirements.
Frey & Winkler GmbH supports projects from the first concept to series production – with experience, innovative strength, and cutting-edge technology.
Our range of services include:
All services are precisely tailored to customer requirements – flexible, efficient, and quality-assured.
Two-shot injection moulding is a forward-looking technology for functional integration, economic efficiency, and intelligent product design. Companies that want to develop their components to be more powerful, assembly-optimised, and material-appropriate benefit from the diverse possibilities offered by this process.
Frey & Winkler is at your side as an experienced implementation partner – with deep process understanding, modern manufacturing technology, and solution-oriented consulting. Would you like to know whether multi-component injection moulding meets your requirements? Please contact us. Together, we will realise the optimal solution for your application.
