Product Descriptions
General Overview - Positioning of the BOY 2C Injection Units
The BOY 2C XS and BOY 2C S are highly compact, independently operated second injection units developed to transform Dr. BOY injection molding machines into multi-component (2K) injection systems. These units are designed to be integrated not only with BOY injection molding machines, but also with injection molding machines from other manufacturers.
The core objective of the BOY 2C concept is to integrate a second plasticizing and injection process into the production cycle without modifying the mechanical structure of the main machine, while ensuring minimal space requirements and maximum process reliability.
Modular and Flexible Positioning Concept
The BOY 2C XS and BOY 2C S injection units can be positioned in various configurations depending on the application:
- Vertical position on the fixed platen
- Vertical or inclined position on top of the mold
- Horizontal position next to the mold (horizontal L-position)
- Sliding vertical position on the fixed platen
This flexibility enables optimal layouts for 2K injection, insert molding, overmolding, sealing applications, and functional coating processes. Especially in production cells with limited floor space, the compact design offers a significant advantage.
Independent Hydraulic Drive and Control Architecture
BOY 2C units are equipped with completely independent hydraulic drive and control systems, separate from the main injection molding machine. The drive unit and control panel of the second injection unit are positioned next to the main machine.
This architecture ensures:
- No impact on the performance of the main injection molding machine
- Independent process parameters for the second component
- Stable and synchronized operation throughout the entire injection cycle
The control systems of both machines communicate via I/O interfaces or dedicated adapter cables, ensuring seamless synchronization during production.
BOY 2C XS - Micro and High-Precision Second Component Applications
The BOY 2C XS has been developed specifically for micro-injection and extremely small second-component applications, featuring an ultra-compact design.
SP 14 injection unit technical data:
- Screw diameter: 14 mm
- Screw L/D ratio: 16.9
- Maximum theoretical stroke volume: 6.1 cm³
- Maximum theoretical shot weight (PS): 5.6 g
- Injection force: 35.4 kN
- Theoretical injection rate: 28 g/s
- Maximum specific injection pressure: 2298 bar
- Maximum screw stroke: 40 mm
- Nozzle contact force: 20 kN
- Nozzle retraction stroke: 100 mm
- Screw torque: 75 Nm
- Screw speed: 340 rpm
- Screw recovery force: 5 kN
- Heating power (nozzle + barrel): 1575 W
- Material hopper capacity: 3 liters
These values make the BOY 2C XS ideal for micro sealing elements, small gasket applications, precision coatings, and micro overmolding processes.
BOY 2C S - Second Component Unit with a Wide Application Range
The BOY 2C S is designed for applications requiring higher shot volumes and a broader material range. It is available with SP 81 and SP 96 injection units.
SP 81 injection unit technical data:
- Screw diameter: 22 mm
- Screw L/D ratio: 17.5
- Maximum theoretical stroke volume: 30.4 cm³
- Maximum theoretical shot weight (PS): 27.7 g
- Injection force: 101 kN
- Theoretical injection rate: 31.5 g/s
- Maximum specific injection pressure: 2656 bar
SP 96 injection unit technical data:
- Screw diameters: 24 / 28 / 32 mm
- Maximum theoretical stroke volume: 43 - 76.5 cm³
- Maximum theoretical shot weight (PS): 39.1 - 69.5 g
- Injection force: 101 kN
- Theoretical injection rate: 37.5 - 66.6 g/s
- Maximum specific injection pressure: 2231 - 1255 bar
- Maximum screw stroke: 95 mm
- Nozzle contact force: 24 kN
- Screw recovery force: 44 kN
- Heating power (nozzle + barrel): 8100 W
- Material hopper capacity: 13 liters
These specifications provide an ideal platform for functional second layers, elastomer overmolding, hard-soft material combinations, and 2K technical components.
Hose Connection and Open Nozzle Design
In BOY 2C units, the open-nozzle plasticizing unit is connected to the second injection unit via adjustable high-pressure hoses (4 m or 6 m lengths). This design offers:
- Freedom in positioning between mold and injection unit
- Easier maintenance and cleaning
- Adaptability to different mold geometries
Control System and Procan ALPHA Integration
The BOY 2C XS and BOY 2C S are fully compatible with the Procan ALPHA control system. The TFT display of the second injection unit can be positioned next to the main machine's Procan ALPHA screen on the operator side.
Control capabilities include:
- 8-stage injection speed control
- 8-stage holding pressure control
- Closed-loop injection and back-pressure control
- Cold-start protection
- Smooth ramp transitions for precise speed control
Energy Efficiency and Compact Dimensions
BOY 2C XS general data:
- Total installed power: 4.6 kW
- Hydraulic system pressure: 250 bar
- Oil tank capacity: 28 liters
- Footprint: 0.57 m²
- Net weight: 320 kg
BOY 2C S general data:
- Total installed power: 7.9 - 11.1 kW
- Hydraulic system pressure: 210 bar
- Oil tank capacity: 28 liters
- Footprint: 1.20 m²
- Net weight: 422 kg
This compact architecture enables multi-component injection even in production environments with limited floor space.
Application Areas
The BOY 2C XS and BOY 2C S are widely used in the following applications:
- Hard-soft (2K) injection molding
- Sealing and gasket overmolding
- Electronic component encapsulation
- Medical and micro-technical parts
- Functional surface coatings
- Insert and multi-component injection molding
Conclusion - Why Choose BOY 2C XS / 2C S?
The BOY 2C XS and BOY 2C S second injection units provide a highly effective solution for multi-component injection molding thanks to their compact design, independent drive and control systems, flexible positioning options, and wide shot volume range. The ability to convert existing injection molding machines into 2K systems significantly reduces investment costs while maximizing process flexibility.
For applications where space constraints, precision, and functional integration are critical, BOY 2C solutions successfully bring Dr. BOY's engineering philosophy into the world of multi-component injection molding.
