Plastics Manufacturing

Plastics
• Plastics contain a high synthetic polymer as
the major constituent (polymers being
materials of high molecular weight formed by
joining together many small molecules)
• Can be easily moulded or shaped by
mechanical or chemical action
• Plastics may be simply defined as materials
made up of long chain molecules based on
carbon and hydrogen
 Chemical structure
Mer
H
C
H

Several Mer’s
combine to form
a chain
H H H H
C C C C
H H H H

Chains can be very long-

103 to 105 mers
 Properties of plastics
Advantages Limitations
• High specific strength and • Low operating temperatures
stiffness • High thermal expansion
• Corrosion resistance • Low strength in comparison
• Good electrical and thermal to metals
insulating properties • Inflammability
• Low coefficient of friction
• Toughness and resilience
• Good vibration damping
properties
 Plastics classification : Thermosetting
• Final shape is formed by • Unsaturated polyesters:
condensation and boat hulls, furniture,
polymerisation of long electrical fittings
chains which undergo • Epoxies and Resins:
chemical change Coating of electrical
• Unaffected by heat or circuits, composites
solvents (fiberglass in helicopter
• more durable, harder, blades, boats, …)
tough, light
 Plastics classification : Thermoplastics
• Polyethylene: packaging, electrical
• Contain linear to branched long-chain
insulation, milk and water bottles,
molecules which are not interconnected • Polypropylene: automotive bumpers,
microwave containers
• Long polymeric chains entangled with • Polyvinyl chloride (PVC): electrical
each other but not bonded together cables cover, credit cards, car panels
• Polystyrene: disposable spoons, forks
• Low melting point, softer, flexible • Polyamide (nylon): textiles and fabrics,
gears, bushing and washers, bearings
• PET (polyethylene terephthalate):
bottles for acidic foods like juices, food
trays
• PTFE (polytetrafluoroethylene): non-
stick coating, raincoats
 Thermosetting
Qualities Thermoplastic
Plastic

Melting point Low High

Tensile strength Low High

High, but
Low, but reform
Thermal stability decompose at high
solids with cooling.
temperatures.

Stiffness Low High

Brittleness Low High

Physical
properties Has ability to retain
Has ability to their rigidity at
recycle, remould or high temperatures.
Reusability
reform upon So unable to
heating recycle or remould
by heating.

Rigidity Low High

Soluble in some Insoluble in organic

Solubility
organic solvents solvents

Durability Low High

 Common processes
– Extrusion
– Injection moulding
– Compression moulding
– Transfer moulding
– Rotational moulding
– Thermoforming
– Casting
 Extrusion moulding
It is a compression process in which material is forced to
flow through an orifice in die to produce long slender
shaper products.
The cross section of product depends on shape of orifice
Used for producing pipes, cables, tubes, coated electrical
wires (most of thermoplatics and rare of thermosets).
Extrusion moulding

Feed

Heat

Melt
Extrusion moulding
 Extrusion moulding
• Thermoplastic pellets or powder are fed through hopper into
extruder barrel with a screw.
• External as well as frictional heating results in softening and
melting of the plastics.
• Screw builds up pressure in the barrel extrudes through die orifice.
• Feed section: material from hopper area into central region of the
barrel;
• Compression section: heat from shearing of the plastic and external
heaters causes melting and extracts the trapped air and materials is
compressed
• Metering section: involves homogenization with pressure buildup
at the die for pumping through die orifice.
 Injection moulding
• In Injection Molding, the Barrel (Cylinder) is Heated to Promote
Melting.
• However, Far Greater Portion of the Heat Transferred to the Polymer is
due to Frictional Heating.
• Pellets or Granules are Fed into the Heated Cylinder, and the Melt is
Forced into a Split-Die Chamber, either by a Hydraulic Plunger or
by the Rotating Screw System of an Extruder.
• As the Pressure Builds up at the Mold Entrance, the Rotating
Screw Begins to Move Backward under Pressure to a Predetermined
Distance which Controls the Volume of Material to be Injected.
• The Screw then Stops Rotating and is Pushed Forward Hydraulically,
Forcing the Molten Plastic into the Mold Cavity. Pressure Range
from 70 MPa to 200 MPa.
• Typical Injection-Molded Products are Cups, Containers, Housings,
Tool Handles, Knobs, Electrical and Communication
Components etc.
Injection moulding

Reciprocating screw type

Injection moulding machine

Plunger type
Injection moulding machine
Injection moulding steps
1. Plastic pellets are poured or fed into a
hopper which stores it until it is
needed.
2. A heater heats up the tube and when it
reaches high temperature a screw
thread starts turning.
3. A motor turns a thread which pushes
the granules along the heater section
which melts then into a liquid. The
liquid is forced into a mould where it
cools into the shape
4. The mould then opens and the unit is
removed.
 Injection Moulding advantages
• CNC closed loop controlling system
• Automatic raw material feed
• Robots for removal of special jobs
• High speed mould clamping mechanism
• High speed mould change over system
• Production control by central computer
• Production data acquisation
Blow moulding
 Blow moulding
• Blow molding is a modified extrusion and
injection molding process for developing hollow
products using a tube called parison.
• Extrusion blow molding, a tube is first extruded,
then after clamping into a mold blowing into the
cavity.
• In injection blow molding, parison is first injection
molded then hot air is injected into the parison
for blowing.
• Typical products plastic beverage bottles and
hollow containers.
 Rotational molding
• Rotational Molding, also called
rotomolding or rotocast, is a
thermoplastic process for producing
hollow parts
• Pre measured powder or liquid
resin is placed into a hollow mold
and then rotated bi-axially in an
oven
• The resin melts and coats the inside
of the mold cavity.
• The tool is cooled and the part is
removed from the mold.
• Typical Parts Made by Rotational
Molding are Tanks of Various Sizes,
Trash Cans, Boat Hulls, Buckets,
Housings, Toys, Carrying Cases etc.
Rotational molding
Thermoforming
 Vacuum forming

A vacuum is formed between the mold cavity and the thermoplastic sheet.
The vacuum pressure (typically 14 psi) forces the sheet to conform to the
mold and form the part shape.
 Pressure forming

In addition to utilizing a vacuum underneath the sheet, air pressure

(typically 50 psi, but up to 100 psi) is applied on the back side of the
sheet to help force it onto the mold.
This additional force allows the forming of thicker sheets and creating
finer details, textures, undercuts, and sharp corners.
 Mechanical forming

The thermoplastic sheet is mechanically forced into or around the mold by direct contact.
Typically, a core plug will push the sheet into the mold cavity and force it into the desired shape.
 Thermoforming
• Thermoforming is a Series of Processes for Forming Thermoplastic Sheet
or Film Over a Mold by Application of Heat and Pressure.
• In this Process, after Heating a Sheet in an Oven to the Sag Point
(Softening but NOT to the Melting Point), it is removed from the Oven,
Placed Over the Mold, and Forced against the Mold through the
application of a Vacuum
• The Mold is usually at Room Temperature, hence the Shape of the Plastic
becomes Set upon Contact with the Mold.
• Because of the Low Strength of the Materials Formed, Pressure
Differential Caused by the Vacuum is Usually Sufficient for Forming,
although Air Pressure or Mechanical Means are also Applied for Some
Parts.
• Typical Parts Made by Thermoforming Include Advertising Signs,
Refrigerator Liners, Packaging, Appliance Housings, and Panels for
Shower Stalls.
Compression molding
 Compression molding
• It is a process in which a molding polymer is squeezed into
a preheated mold taking a shape of the mold cavity and
performing curing due to heat and pressure applied to the
material.
• The method is used mostly for molding thermosetting
resins (thermosets), but some thermoplastic parts also
• The method uses a split mold mounted in a hydraulic press
• Compression Molding Results in the Formation of Flash,
which is Subsequently Removed by Trimming or by Other
Means.
• Typical Parts Made are Dishes, Handles, Container Caps,
Fittings, Electrical and Electronic Components, Washing
Machine Agitators, and Housings.
Transfer molding
 Transfer molding
A piece thermoset is placed into a portion of the mold called the "pot."
The plunger (on the top-most part of the mold) fits snugly into the
"pot."

The mold is closed up and under hydraulic pressure the rubber is

forced through the small hole (the "gate") into the cavity. The
mold is held closed while the rubber cures.

The plunger is raised up and the "transfer pad" material may be

removed and thrown away.

Mold is opened and the part can be removed. The flash and the
gate may need to be trimmed.
 Transfer molding
• Charge (preform) is loaded in chamber ahead of mould
followed by heating and pressure application to force
softened polymer to flow into the heated mould where
curing occurs.
• This process results in scrap in form of left over materials
called “cull”
• Mainly used for thermosets and elastomers
• There are variants of the process based on how charge
enter the mould
– Pot transfer moulding: (vertical channels)
– Plunger transfer moulding (lateral channels)
Pot transfer and plunge transfer
 Casting
• Some Thermoplastics (i.e., Nylons and Acrylics) and Thermosetting
Plastics (i.e., Epoxies, Phenolics, Polyurethanes, Polyester) can be
Cast, in either Rigid or Flexible Molds, into a Variety of Shapes.
• Typical Cast Plastic Parts are Gears, Bearings, Wheels, Thick Sheets,
Components Requiring Resistance to Abrasive Wear.
• In the Conventional Casting of Thermoplastics, a Mixture of
Monomer, Catalyst and Various Additives is Heated and Poured into
the Mold. The Part Forms after Polymerization Taking Place at
Ambient Pressure. Intricate Shapes can be Produced with Flexible
Molds, which are then Peeled Off.
• Centrifugal Casting: This Process is also Used with Plastics,
Including Reinforced Plastics with Short Fibers. Thermosets are
Cast in a Similar Manner; Typical Parts Produced are Similar to
those Made by Thermoplastic Castings.
 Potting and Encapsulation
Potting Encapsulation
• Potting is the process of • Encapsulation requires a
environmental protection mold in which the device is
by pouring a hardenable to be protected are placed,
polymeric material into an after which the hardenable
electronic device, totally polymeric material is
submersing and protecting injected to completely fill
the internal parts. the mold.