Injection Moulding

Process
 DESCRIPTION
Injection molding makes discrete parts that can have complex and variable cross-sections
as well as a wide variety of surface textures and characters.

Working principle of injection molding machine is,

The Material after being heated and plasticized in the barrel, then it will be
injected into the mold, the final products will be formed after cooling.

Mould Movements
Ejectors Nozzle Unit Metering/
Plasticising
Injection
Core Pull
Injection Molding Process

C I PE T
 MACHINE OPERATION SEQUENCE
The mould closes and the screw begins moving forward for injection.

The cavity fills as the reciprocating screw moves forward, as a plunger.

 Conti…

The cavity is packed as the screw continuously moves forward.

The cavity cools as the gate freezes off and the screw begins to retract to
plasticize material for the next shot.
 Conti…

The mould opens for part ejection

The mould closes and the next cycle begins

MOULDING PROCESS - RESOURCES

 MATERIAL
 MACHINE
 MOULD
 MAN POWER
 MATERIAL
THERMPLASTIC MATERIAL :
SOFT
HEAT COOL SOLID

PRESS.

IT CAN BE RECYCLED

THERMOSET MATERIAL :

SOFT HEAT SOLID

HEAT CHARCOAL
x
PRESS.

IT CAN NOT BE RECYCLED

 MACHINE
 Heating
 Pressurizing and conveying
 Mould clamping

HEATING INJECTING MOLDING

The Basic Injection Molding Cycle

 MOULD

THE MOLD HAS 4 MAIN FUNCTIONS

RECEIVE & DISTRIBUTE THE MATERIAL

SHAPE FORMING

COOLING(Water & oil)

DISPOSAL
 MANPOWER

 TO SET UP A PROCESS

 TO MONITOR AND TROUBLE SHOOT

 TO OPARATE MACHINE
 Injection Moulded Items

PP tubs
DVD player holder

Warning Light

Gear Wheels Hair Dryer Housings

 Injection Moulded Items

Thermoplastic elastomeric tooth set

Pipe Fittings

Safety Helmets
Advanced Injection
Moulding Processes
 Gas Assisted Injection Molding
Gas Assist Injection Molding is a low-pressure process utilizing
nitrogen gas to apply uniform pressure throughout the molded
plastic part.

Through the gas channels, pressure is transmitted evenly across

the part, eliminating warpage, sink marks and internal stress. As a
result, reductions in clamp tonnage, cycle time, and part weight are
realized while the strength and rigidity of the part is increased.
increased.

Principle :
It is the process of injection of molten plastics assisted by the
introduction of pressurized gas (usually nitrogen) into the
mould. The gas produces a bubble which pushes the plastic
into the extremities of the mold creating hollow sections as
the bubble propagates.
 Methods of Gas Injection

Two most common methods

 Gas Injection through-the-nozzle
 Gas injection via gas pins, or "in-article” in a tool

Animated representation of Gas injection through the Nozzle :

 Animated representation of Gas injection through gas pins :
C I PE T

Applications :
 Coring of ribs in rigid panels such as crates, tables, frames, mounting plates
and covers
 Tennis racquet, bent tubes and toilet seats
 GAIM sample products

This part was originally molded in

structural foam. With gas assist we were
able to reduce the shot weight by Thin wall parts can be molded warp
1 pound, reduce cycle time by 34%, and free, without sinks, and with fewer
limit the paint process to 1 coat. gates.

Thick sections can be cored out

with gas assist reducing part
weight and cycle time.
 Insert Injection Molding Process
Insert Molding replaces metal and plastic assemblies, and components
made solely of plastic or metal. This unique manufacturing process
combines metal and plastic, ceramics, or multiple combinations of materials,
components and plastic into a single unit.

C I PE T
 Thin Wall Injection Molding

Thin-wall technology is a recently developed and cost-

effective plastic design technology for making thin wall
thickness articles Saves material due to reduced wall-
thickness.
Using thin-wall technology
Material saving is done.
Cooling time is short.
 Optimize cycle time
Miniaturization of product
 The reduction of component thickness is limited by the
following conditions:

 Melt flow behavior

 Max. injection pressure
 Component strength
 standards, legal regulations

The advantages of thin wall molding can be achieved by:

 Selecting suitable materials
 Material knowledge
 Strictly using rheological simulation programs
 Suitable part design and tool design
 Reaction Injection Molding
 Polyurethane rigid foams are produced by RIM process.
 Urethane foams are in general produced by the reaction
of a isocynate and polyol (either polyester polyols or
polyether polyols)
 The reaction between the isocynate & polyol produces
the urethane resin.

0

R–N=C=0+
+R'
R' – OH RNH CO – R'
Urethane
  A further reaction between a slight excess of isocynate
and water added to polyol then produces CO2 gas to
form cellular structure of foam.

R – N = C = 0 + H2O RNH – COOH R –NH2 + CO2 

Carbonic acid

 But this was the original method adopted ,

 A low boiling inert liquid flouro carbon is mixed with

polyol.
 When polymerization reaction takes place, the exotherm
is sufficient to cause the flouro carbon to volatiles and
act as a blowing agent to form the cell.

 In addition to blowing agent, a catalyst (Organo tin

compound) used to accelerate the rate of reaction so
gelation takes place before gas is dissipated;

 A surfactant (silicone liquid) used to obtain uniform cell

structure are also added.
 RIM EQUIPMENTS :

 Raw material storage area

 Metering equipment

 Mix head

 Molds

 Clamping units

 Post demoulding operations

 REACTION INJECTION MOLDING

RATIO CONTROL M
E
T
E
MIX HEAD R
I
A B N
G

D
E
V
I
C
E

Component A  Iso cynate ( MDI, TDI)

Component B  Polyol, Organotin compound, Silicone liquid, Freon -11
 APPLICATIONS

This technique was developed for the production of

Bumper and fascias or the front and rear ends of

automobiles.

Fenders, panels, arm rests, steering wheels.

Shoe soles, frames.

Beer keg ends.

Cushions
RIM Products
 MuCell Technology
MuCell Technology is an improved processing method of foamed Injection
moulding.

Environmentally compatible gases are dissolved uniformly in the melt. When the
cavity is filled, nucleation occurs and the gas bubbles expand to yield
microfoaming containing trapped gas bubbles.
Why MuCell for Injection Moulding?

FOR PARTS FOR PROCESSING

 Lower Cost  Lower Costs
 Less Material  Faster Cycle times
 Thin Wall Components  Reduce clamp tonnage
 Dimensional Stability  Drop injection Pressures
 Eliminate sink marks  Cooler melt Processing
 MuCell Process features

 To foam very thin sections (0.5mm/0.20inch)

 Production microcellular foams (5-50 micron
ranges) using supercritical fluids (SCFs).
 No need for chemical or hydrocarbon-based
blowing agents
 Generates evenly distributed microscopic cells
throughout the plastic
Special Benefits:

 Parts are of lighter weight

 Less Residual Stress in the parts
 Good dimensional stability and accuracy
 Cycle times are shorter than conventional process
 Less material consumption
 Materials moulded with lower MFI
 Increased cavitation per ton of clamping force
 Co – Injection Molding

Why Co-Injection?
 Improve Part Physicals
- High Strength cores with soft skins
 Reduce Cost
- Inexpensive material hidden inside
 Decorative
- Attractive user friendly skin surface
 Innovative Solution
- Reduced assembly cost
 Sandwich Moulding

Basic Co-Injection Process

Core Skin

Frozen “Skin” Layer

Sandwich Moulding - Process sequence
 Two-Material Co-Injection Molding
By two-material co-injection molding we mean the injection of two
different melts into the mold, one after the other. They may comprise the
same material in different colors or two different materials. Other terms to
describe this process are two-color co-injection molding or two-component
sandwich molding.
The principle is basically the same, although there are essentially four
different methods of carrying out the co-injection molding process. We can
divide them first of all into rotating and non-rotating mold systems.

 Rotating mold
 Turnstiles and rotating cores
 Transfer technique
 Core-back technique
 Three-color and three-material
co-injection molding
 To manufacture, for example, car rear lights, three or more different
components are needed.

 For this and similar cases of application, the three-color or three-

material co-injection molding method is used.

 This process is comparable to the previously described two-material co-

injection molding process as far as the mold technology, processing and
machinery are concerned.

 All that is needed in addition is a third injection unit and a suitable mold
with a gating system for the three components, which of course is
correspondingly more complex.

 Continuing this principle, several plastics can be combined together to

create one part (multi-color co-injection molding).
 Processing Methods
Rotating Mould:
Mould:
 It is some time called double colour moulding
 This process done in two stage
 In first stage ,one colour of molten material is injected
into the mould
 After the first moulding is over the core half is rotated at
180 degree
 With the help of rotating table
 In the second stage another colour of molten material is
injected on the first moulding
 The mould rotate again 180 degree then the finished
product is ejected
Rotating Mold Process
 CO-INJECTION-I

 It is a developed process in multicolor injection

moulding

 Two injection units connected with a common nozzle

 Two material injection time is programmed In such way

to control the quality and thickness of the different
color (or) diff.Material for a moulding

 The mould need not have two station

 A standard mould is enough for this process

 Clamping mechanism ,injection mechanism are same

as a commercial injection moulding machine
 CO-INJECTION-II
 It is a latest development process
 It is having single injection unit and two hoppers
 Plastication of both components takes place on a
single screw with two stage
 Melt from the first section passes through a central
channel in the section and exits at the nozzle
 The ratio of the material is controlled by an external
pellet feeder
 The pellet feeder is mounted to one of the two hopper
 Both materials are plasticated simultaneously
 The barrels larger than 45 mm because of the space
needed to fit two screws with single barrel
Blow Moulding Process
 DESCRIPTION

Blow molding is a plastic forming process that is especially well suited

for the manufacture of bottles and other simple, hollow-shaped parts.

Based on the method used to create the parison or preform, two types of
blow moulding are recognized.

 Extrusion Blow Moulding that uses an extruded tube.

 Injection Blow Moulding that uses an Injection Molded preform.

Extrusion Blow Molding Machine
 Extrusion Blow Molding Process

C I PE T
 Injection Blow Molding

An ideal combination of Injection & blow moulding.

It includes three stages:

 Formation of preform by using injection moulding.

 Transferring the preform into the blow moulding.

 Passage of air or gas pressure through the core rod to blow the
thermoplastic resin into the cavity walls of the blow mould.
Injection Blow Molding Process
 Plastic Jars
Soda bottles

Liquor bottles Cosmotic

bottles
Advanced Blow Molding
Process
 Injection Stretch Blow Molding Process
Stretch Blow Molding (SBM)
Molding (SBM) process, the plastic is first molded into a "preform" using the injection
molding process.
These preforms are heated (typically using infrared heaters) above their glass transition
temperature, then blown using high pressure air into bottles using metal blow molds.
Images for SBM
Extrusion Process
 DESCRIPTION
A word “extrusion“ comes from Greek roots that mean to “push out”.
This phrase correctly describes the extrusion process, which is, in
essence , a pump that supplies a continuous stream of material to a
shaping tool or to some other subsequent shaping process.
Extrusion video
Blown Film Process
 Film blowing is the most
important method for producing
Polyethylene films (about 90% of
all PE film produced)

 In film blowing a tubular cross-

section is extruded through an
annular die (usually a spiral die)
and is drawn and inflated until the
frost line is reached. The extruded
tubular profile passes through one
or two air rings to cool the
material.

 Most common materials: LDPE,

HDPE, LLDPE
Corrugated Pipes & Profile
Extrusion Process
 CORRUGATED PIPES
 The characteristics of corrugated plastic pipes depend
on profile and material.
 Corrugated pipes have either parallel ring grooves or a
continuous helical groove.
 The pipes design can be single walled or twin walled.
 Most common thermoplastics are PVC, PE,PP, PA and
fluoropolymers.
The most important advantages are
 Considerable raw material savings
 High pressure resistance with good flexibility.
 High impact strength
 Good hydraulic characteristics
 Process
Small points
Essentially to extrusion of pipes except that the die and the
calibration units are specially designed to produce corrugation
on the pipes.

The cylindrical part of the pipe die head extends into the
closed area of a revolving mould block chain. The plastic tube
is pressed against the profiled, revolving mould block halves
by internal air pressure or by vacuum calibration.

As it passes through the forming machine, it is cooled by

contact with the mould blocks, and by that time it reaches the
end of the chain, the tube must be sufficiently cooled to leave
the rotating mould blocks in a stable form.
A. INTERNAL PRESSURE SYSTEM

B. VACUUM SYSTEM
Double walled corrugated pipe production:

The manufacturing process is the same as with

standard corrugated pipes, but when the first tube has
been formed, the second tube is laid smoothly on the
inner surface of the still plastic corrugation and
welded to the first with the aid of a sizing mandrel.
Twin walled corrugated pipe production
Video
 Applications of Corrugated pipes
 Conduits for cable protection, TV,Telephone, Glass fibre, power,
control and computer lines, automobiles, machines and planes,
protective pipes and conveyor pipes.
 Drain pipes for fields, streets, squares and houses.
 Pipes for vacuum cleaners, washing machines, dish washers,
medical application – drip irrigation, hoses for fields, hot houses
and plantations.
 Protection pipes for district heating, domestic connection lines,
structural and civil engineering.
 Large size pipes for sewage, waste water, control shafts and
conveyor pipes.
Corrugated pipes are produced with diameters form 3\5 to
2000mm.
Double wall corrugated pipe
PVC – HDPE Double wall
corrugated pipe

PVC corrugated pipe

PVC flexible corrugated pipe
 Profile extrusion
 Extrusion of odd shape cross-section is called profile
extrusion.

 Depending upon the material to be processed either SSE

or TSE is to be used.

 Profile are extruded horizontally through the die of

corresponding cross section are cooled , sized with air
jet or water troughs or cooling sleeves and mechanical
aids then are cut into desired length.
Extrusion Molded Profiles
Profile extrusion video
Thermoforming Process
 DESCRIPTION
Thermoforming is a process used to shape thermoplastic sheets and
films into discrete parts.

The basic principles of the thermoforming process are to heat a

thermoplastic sheet until it softens and then force the hot and pliable
material against the contours of mold by using either mechanical, air,
or vacuum pressure.
Vacuum forming process
Thermoforming process

C I PE T
Continuous Thermoforming Process

Simulation Thermoforming Process

Products made by thermoforming process
Rotational Moulding
Process
 DESCRIPTION
The Rotational Molding Process, often called rotomolding, uses the
rotation of a mold in a heated chamber to form the part,

Rotational molding is ideally suited to the formation of very large,

seamless, and stress-free hollow parts such as 25,000 gallon
agricultural tanks, although the process has also been used to make
parts as small as ping pong balls.

The process uses no pressure and so the molds can be simple and
inexpensive.

Most process that use no pressure are called casting or cast molding.
In that sense, rotational molding is a type of casting and is sometimes
called rotational casting.
Bi - Axial Rotational Molding Machine
Rotational molding process

C I PE T
Casting Process
 DESCRIPTION
Casing Processes are characterized by the use of a liquid or powder
starting
material that is shaped without the application of significant pressure.

The absence of pressure is such an important characteristic of

casting process for forming plastics that do not use pressure might
be considered casting processes.

Different types of casting processes are as follows

 Mold Casting
Slush Casting
Dip Casting
Static Powder Casting
Cell Casting
Continuous Casting
Film Casting or Solvent Casting
Foaming Process
 DESCRIPTION
Foaming Processes characterized by techniques that cause tiny
bubbles to form within the plastic material such that plastic solidifies
the bubbles, or at least the holes created by the bubbles, remain.

The solidified bubble containing material thought of as a cellular

structure.

The products made by these processes are referred as Foams or

cellular plastics.

Two types of cell structures occur in cellular plastics, those are

Closed cell structure

Open cell structure
Structural foaming process
C I PE T
 EPS foaming process
C I PE T
Compression Molding
Process
 DESCRIPTION
Compression Molding, also called matched-die molding, is a molding
process used almost exclusively for molding thermoset materials.

The principles of compression molding are quite simple.

A charge of thermosetting resin is placed in the cavity of a mold that

is in the open position.

The mold is closed by bringing the male and female halves together,
and pressure is exerted to squeeze the resin so that it uniformly fills
the mold cavity.

While under pressure, the material is heated, which causes it to

cross-link and to harden.

When the material is hard, the mold is opened and the part is
removed.
SMC compression molding process

C I PE T
Transfer Molding Process
 DESCRIPTION
Transfer molding is a method of molding Thermoset materials in a
closed mould.

In this process the Thermoset resin is placed into a transfer chamber

where the resin is heated until liquid.

A plunger then forces the liquid resin through a sprue and runner
system into the mould cavities.

The heated mould is closed during the transfer process to allow the
part to cure and solidify.

After an appropriate time, the mold is opened and the part is ejected.
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