At Thomas Dudley, we are dedicated to pushing the boundaries of moulding technology to provide exceptional solutions for manufacturers. Our Combi-Mould, also known as the Sandwich Injection Moulding Machine, is a testament to this commitment, offering unmatched capabilities and advantages that distinguish it from other machines on the market.
Key Features of Our Combi-Mould Machine:
- 550T Clamping Force: Delivers strong and precise moulding.
- Minimum Mould Height of 450mm: Supports a variety of mould sizes.
- 2000mm Maximum Daylight: Accommodates larger moulds with ease.
- 2 Core Pullers: Enhances the complexity and functionality of moulded parts.
- 85mm Screw Diameter: Ensures efficient material processing.
- 2400cm³ (420mm) Shot Volume (per barrel): Allows for significant material injection.
- 2 Adaptive Sandwich Plates: Minimizes material wastage during colour changes.
- Nozzle Adjustment on Sandwich Plates: Eliminates the need for tooling modifications.
- Core Material Compatibility with Up to 100% Regrind Material: Promotes sustainability and cost-efficiency.
- Metal Separators Fitted to Both Barrels: Ensures material purity.
- Maguire Gravimetric Blenders on Both Barrels: Guarantees precise material blending.
- Platen Dimensions of 1400x1200: Supports large-scale moulding operations.
- Fitted with a 5-Axis Robot: Enhances automation and precision.
Applications and Benefits
Sandwich Injection Moulding is a ground-breaking process that enables the use of two different materials in a single moulding cycle. This technique offers several key advantages:
Cost Reduction: Utilizing regrind material for the core significantly lowers the overall cost of moulding. High-quality virgin materials, such as Polystyrene (£1700/ton) and Polypropylene (£1500/ton), are used only for the outer skin, ensuring a premium finish where it matters most.
Material Efficiency: Adaptive sandwich plates reduce material wastage during colour changes, making the process more efficient and environmentally friendly.
Versatility: The machine’s ability to handle up to 100% regrind material for the core allows for the recycling of scrap mouldings, further reducing costs and promoting sustainability.
High-Quality Finishes: Ensures that the outer skin of moulded parts meets high visual and quality standards, essential for customer satisfaction.
Real-World Example
Consider a part weighing 2.2kg made entirely from virgin material, costing approximately £3.718. With our Sandwich Injection Moulding technology, where 60% of the material used is regrind, the cost of virgin material reduces to £1.487. This substantial cost saving highlights the economic benefits of our machine.
Capacity and Quick Turnaround
At Thomas Dudley, we understand the importance of efficiency and speed in manufacturing. Our facility is equipped with ample capacity to handle large-scale projects, ensuring that we can meet your demands without delay. Our streamlined processes and advanced technology enable us to turn around jobs quickly, helping you stay ahead of your production schedule and market demands.
Expert Training and Professionalism
Our commitment to excellence extends beyond our machinery. All our professional operators and maintenance engineers undergo advanced training to ensure they are proficient in the latest moulding technologies and best practices. This rigorous training program guarantees that our team can operate and maintain the Combi-Mould machine at peak performance, providing you with reliable and high-quality moulding solutions.
Design Expertise
In addition to our state-of-the-art machinery, we have a talented team of designers who can bring your product from concept to reality. Our designers work closely with you to understand your vision and requirements, ensuring that every detail is meticulously planned and executed. From initial sketches to final production, our team is dedicated to delivering innovative and functional designs that meet your exact specifications.
Conclusion
The Combi-Mould machine at Thomas Dudley is engineered to deliver high-quality, cost-effective, and sustainable moulding solutions. Its advanced features and capabilities make it the ideal choice for manufacturers aiming to optimize their production processes and reduce costs. By choosing our machine, you are investing in a technology that not only meets but exceeds industry standards, ensuring your products stand out in the market.
For more information or to see our machine in action, please contact us. Let us help you achieve excellence in moulding.
We’d be delighted to arrange a demonstration or a visit to our facility!
