- Process: Two-Shot Molding (Double Injection)
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- Material: PC + Silicone (LSR)
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Project Overview: A global premium water sports brand sought to develop professional swim goggles that combine sleek aesthetics with ultimate comfort. Traditional methods, which involve manual gluing of the rigid frame to the soft seal, often lead to leakage, messy glue residue, and material separation over time.
The Challenges:
- Zero-Leakage Requirement: The interface between the rigid and soft materials must achieve a molecular-level bond to ensure 100% water-tightness under pressure.
- Ergonomic Comfort: The eye gasket needs to be extremely soft for long-wear comfort, while the structural frame must maintain rigidity.
- Aesthetic Precision: The parting line between the two colors must be razor-sharp, with no burrs or color bleeding.
Our Solution by Yistar: We implemented an advanced Rotary Two-Shot Injection Molding process:
- Mold Engineering: We designed a high-precision rotary mold. The first shot injects the rigid PC frame; the mold then rotates 180° for the second shot of soft Liquid Silicone Rubber (LSR).
- Material Science: We selected surface-modified PC and self-adhesive medical-grade silicone to achieve a strong chemical bond without the need for primers or adhesives.
- Seal-off Optimization: Through micron-level adjustments of the seal-off areas, we eliminated the risk of flashing during the high-pressure second injection.
The Results:
- Efficiency Gains: By eliminating manual assembly and secondary gluing, production efficiency increased by 40%.
- Superior Durability: The product passed 5,000 tension cycles without any sign of delamination between materials.
- Market Success: With its seamless, high-end finish, the goggles became the brand’s top-selling model within six months of launch.
