Multi-injection mould design for automotive components: A case study

The metalworking and mechanical engineering industry plays a crucial role in the national economy, particularly within the Portuguese industrial hub of Oliveira de Azeméis, where a case study of a precision mold manufacturer operates with internationally recognized quality in the automotive industry. The manufacturers tackle the inherent uniqueness of each mold, which presents distinct challenges in specifications, geometric complexity and mixes of materials. The main goal of this work is to present the complex and complete reality of the design and manufacture of a rotary bi-material injection, capable of sequentially injecting plastic and rubber, presenting a recent and advanced technology within the automotive component manufacturing. The manufacturing of a bi-material rotary mold represented a highly engaging and accomplished challenge, both in terms of meeting project timelines and addressing the inherent difficulties posed by the geometric complexity of the components. These findings demonstrate and underscore the importance of integrating material selection, manufacturing innovation, and precision engineering in high-complexity mold production. The insights gained contribute to forward-moving the design and manufacturing of more complex injection molds, providing valuable insights for academics, practitioners, and industrial researchers regarding bi-material advanced injection molding technology applied on an industrial scale.