A method is provided for producing a decorative structural plastic part. That method includes the steps of two-shot molding a structural plastic layer with a decoration-compatible plastic layer, mechanically bonding the structural plastic layer with the decoration-compatible plastic layer to form an integral plastic part body and applying a decoration to the decoration-compatible plastic layer following molding.

A decorative structural plastic part is provided. That part includes an integral body having a structural plastic layer, a decorative face formed from an in-mold-decoration or IMD and an IMD-compatible plastic layer bridging between the structural plastic layer and the IMD. A mechanical bond locks the structural plastic layer with the IMD-compatible plastic layer. A method for making the part is also disclosed.

A method of making an integrated depth sensor window lens, such as for an augmented reality (AR) head set, the depth sensor window lens comprising a sensor lens and an illuminator lens separated by an opaque dam. The method uses a two-shot injection molding process, a first shot comprising an optically clear polymeric material to form the sensor lens and the illuminator lens and the second shot comprising an opaque polymeric material to form the separator of the two.

An injection molding method includes providing a molding device including a first mold, a second mold over the first mold and a first mold cavity defined by the first mold and the second mold; injecting a first material into the first mold cavity; forming a first layer from the first material; replacing the second mold by a third mold, injecting a second material into a second mold cavity defined by the first mold and the third mold; and forming a second layer from the second material, wherein the second layer at least partially contacts the first layer. The first material is same as the second material.

An actuating member (14), in particular a handle element, an interior door handle arrangement of a vehicle, wherein the actuating member (14) includes a carrier substrate (20) preferably made of plastic and a decorative layer (21) covering the surface of the carrier substrate (20). The decorative layer (21) includes a visible area (22) that in particular in the intended installed state, and in particular in the non-actuated state of the actuating member (14) forms a visible side of the actuating member (14), at least one gate region (2) in particular formed in a gate lip or gate tab (4), and at least one edge region or arcuate region (25, 26) by which the gate region (2) is preferably continuously connected to the visible area (22) of the decorative layer (21).

An imaging lens assembly includes a dual molded optical element, a plurality of imaging lens elements and a light blocking element. The dual molded optical element has an object-side surface and an image-side surface and includes a light transmitting portion and a light absorbing portion. The light transmitting portion includes an optical effective section. The light absorbing portion is located on at least one of the object-side surface and the image-side surface of the dual molded optical element, and a plastic material of the light absorbing portion and a plastic material of the light transmitting portion are different colors. The imaging lens elements are disposed in the inner space of the imaging lens assembly. The light blocking element is disposed adjacent to the light transmitting portion of the dual molded optical element.

The invention relates to a method of manufacturing a heart valve, comprising: a step of injection moulding a first part (110) of the heart valve from a first block-copolymer, wherein the injection moulding is performed at a temperature below an order-disorder transition temperature of the block copolymer, such that a phase structure is present in the molten block-copolymer; a step of injection moulding a second part (114) of the heart valve from a second block-copolymer that is different to the first block-copolymer, by over-moulding over the first part (110) to form an over-moulded structure, wherein the injection moulding is performed at a temperature below order-disorder transition temperatures for the first and second block copolymers, such that a phase structure is present in the molten second block-copolymer and remains present in the first block-copolymer; and a step of cooling the over-moulded structure, without heating it above the order-disorder transition temperatures between the step of injection moulding the second part (114) and the step of cooling, so as to preserve an arrangement of the phase structures created during the steps of injection moulding and produce anisotropic physical properties in the second part (114). The invention also relates to the thus manufactured heart valve.

Some embodiments relate to a method for the direct soling of a multilayered shoe sole. The method can provide two distinct sets of mold frames for a first and a second shoe sole layer and a distinct order for the soling of the layers. In contrast to art traditional approaches, a first layer (e.g. a midsole) is first soled to an upper in a first mold frame and subsequently a second layer (e.g. an outer sole) is soled onto said first layer in a second mold frame. The method can allows for an increased design flexibility and the inclusion of additional functional or aesthetic features, such as air pockets, undercuts, toe caps or running sole tips previously not possible with direct soling processes. Some embodiments relate to an injection molding system equipped and configured for carrying out the method.

A method relates to manufacturing an in-mold decorative molded product including a transfer layer formed on a surface of an injection-molded product. The method includes inserting, in a first mold for injection molding, an in-mold transfer film including the transfer layer disposed on a base film; forming a molding injection space by mold clamping of the first mold and a second mold including a structure for injecting a molding resin into the molding injection space and a structure for holding the in-mold decorative molded product; and forming the in-mold decorative molded product by filling the molding injection space with the molding resin and then opening the first and second molds. When the base film is separated from the in-mold decorative molded product by opening the first and second molds, a peeling weight varies depending on a portion in an end part of the in-mold decorative molded product.

Exemplary embodiments are provided of molding designs and methods for helical antennas. In an exemplary embodiment, a method generally includes placing an antenna element between a top mold core and a first bottom mold core, and injecting molding material into a first mold cavity defined by at least the top mold core, thereby forming a top portion of a helical antenna housing and two opposite side portions of the helical antenna housing. The method also includes removing the first bottom mold core and placing a second bottom mold core about the antenna element, and injecting molding material into a second mold cavity defined by at least the second bottom mold core, thereby forming a bottom portion of the helical antenna housing.