What is Injection Moulding?
Injection moulding is a process that uses high pressure to inject molten plastic into a mold. The plastic is forced through a nozzle, cooled and solidified before being ejected from the mould. Machinery for mold fabrication finds application in numerous sectors like automobile, electronic equipment, medical apparatus, and consumer products.
Advantages of Injection Moulding
Cost-effective way to create large numbers of parts
The cost-efficient aspect of manufacturing numerous components renders it perfect for sectors that require the rapid creation of multiple items.
We fabricate molds with extraordinarily precise limits that yield components exhibiting minimal discrepancies. This ensures that every part will match the next one exactly, providing essential consistency in your products. This feature is especially crucial if you need your product to align perfectly with a piece from another manufacturer’s line.
Injection moulding’s machine fleet
KB Components has nearly 300 mold fabricating apparatus, spread across eight distinct locations.
- Injection moulding 25–2700 tonnes
- Injection compression moulding
- Compression moulding
- Back injection moulding on textiles
- 2K injection moulding 100–1000 tonnes
- Clean-room injection
- Clean-room assembly
Well-established standard procedure for manufacturing of plastic parts.
The KBC group boasts mold fabricating devices with a clamping capacity ranging from 25–2700 tonnes.
Injection Compression Moulding
The philosophy of injection-compression mouldings – the injection of thermoplastic polymer melts into a slightly opened mould with simultaneous or subsequent compression by an additional clamping stroke.
We use a technology in which the additional stroke is accomplished via an integrated hydraulic booster inside the mould.
Compression moulding using ICM
Here, we use the injection moulding machine to create the compression.
First, the material is injected when the tool is open. When 80% of the tool is filled, the tool is closed and the final step is compression.
This method is commonly used for thin wall thicknesses and long flow paths.
(Creates less internal stress and reduced warpage.)
Back injection moulding on textiles
Multilayer polyester fabric inserted in tool.
Back injection with PC/ABS.
2K injection moulding
There are different methods for injecting two chemically compatible materials.
Rotating tool (genuine 2K solution optimum condition).
Rotating with index plate (genuine 2K solution optimum condition).
Move with robot into second insert (semi-genuine 2K solution).
Pre-produced part components put into 2nd mould and over-injected by second material (false 2K).
The KBC Group has 2K injection moulding machines in clamping forces from 80-1000 tonnes.
Commonly used when high torque is required on threads/screw.
The inserts may be over-moulded or mounted after injection.
Our unique offer
KB Components differs from most of our competitors by having a focused approach to injection moulding technologies, including material technology and design optimization of both the part and the process. By combining our global resources, we give you access not only to a global manufacturing set-up but also to our internal material labs, measuring centres and production technology teams. When your business grows, we have the resources to grow with you and to follow your globalization by providing local production in Asia, Europe and North America. If your product will be assembled with other parts, we also offer complete solutions for production and assembly. Most of the time, this is integrated with the injection moulding operation, using the most modern robot technologies in order to create a cost-efficient production set-up.
At the same time, you can rely on our Code of Conduct, in which we pledge to follow the most stringent regulations for environmental protection and work safety. Apart from being certified according to environmental standards, all our units are also recognized as a “Great Place to Work”, with a vast majority of employees showing high work satisfaction and engagement – to the benefit of all our customers.
Our strategy has proven to be successful and is based on:
A Global Footprint, Technological Leadership and Operational Excellence
Together with our customers, we create “Value Through Innovation”