9

Compression and Transfer

Molding

COMPRESSION MOLDING mold. The two parts of the mold are brought
together under pressure. The compound, soft-
Historians cannot establish definitely the date ened by heat, is thereby welded into a contin-
of origin of the art of molding. It might be said uous mass having the shape of the cavity. The
that the art of molding originated with prehis- mass then must be hardened, so that it can be
toric humans, when they learned how to make removed without distortion when the mold is
pottery from clay, using the pressure of their opened.
hands to form the shape and the heat of the sun If the plastic is a thermosetting one, the
to harden the clay. hardening is effected by further heating, under
The earliest application of compression pressure, in the mold. If it is a thermoplastic,
molding as a manufacturing process occurred the hardening is effected by chilling, under
early in the nineteenth century, when Thomas pressure, in the mold. (The procedure is de-
Hancock perfected a process for molding rub- scribed in greater detail later in this chapter.)
ber. The first patent on a process of molding in Compression molding is used principally for
the United States was issued in 1870 to John thermosetting plastics, and much less com-
Wesley Hyatt, Jr. and Isaiah S. Hyatt. monly for thermoplastics (for which injection
Dr. Leo H. Baekeland's development of is the preferred method of molding).
phenol-formaldehyde resins in 1908 gave the
industry its first synthetic molding material, Thermosetting Materials. Thermosetting
which even today is one of the principal ma- materials are chemical compounds made by
terials used in the compression molding pro- processing a mixture of heat-reactive resin with
cess. fillers, pigments, dyestuffs, lubricants, and so
on, in preparation for the final molding opera-
Technique and Materials tion. These materials or molding compounds
are, in most cases, in powder, granulated, or
The process of compression molding may be nodular form, having bulk factors ranging from
simply described by reference to Fig. 9-1. A 1.2 to 10. Some are used in the form of rope,
two-piece mold provides a cavity in the shape putty, or slabs.
of the desired molded article. The mold is The materials of lower bulk factor are usu-
heated, and an appropriate amount of molding ally those having wood flour or mineral com-
material is loaded into the lower half of the pounds as fillers, whereas those of higher bulk
factor have as fillers cotton or nylon flock, rag
Reviewed and revised by John L. Hull. Vice Chainnan, fibers, pieces of macerated rag, tire cord, sisal,
Hull Corporation, Hatboro, PA. and, for very high impact strengths, glass rov-

251
252 SPI PLASTICS ENGINEERING HANDBOOK

"MO'D~
~_______ ~~~~E ~~~~~~~~~~~~
MOLDING
COMPOUND

MOLD
CAVITY

MOLD OPIN MOLD ClOSED

Fig. 9-1. Basics of a two-piece fully positive compression mold. (From Plastics Mold Engineering)

ings, carbon fibers, boron fibers and Kevlar mechanical pressure, as in a closed mold, the
fabric. resulting material is a dense solid. Polymer-
Phenol-fonnaldehyde is the single most ization generally is a time-temperature rela-
common resin and catalyst combination, gen- tionship, with shorter cure times when higher
erally called phenolic molding compound. If temperatures are used. Typical pressure, tem-
the filler is mineral, such as mica, the molded perature, and time values for a phenolic wall
part will have good electrical properties. If the socket in semiautomatic compression molding
filler is glass fibers, say one-quarter inch long, might be 3000 psi, 300 o P, and l~ minutes.
the molded part will have good impact strength.
Small hollow glass micro-balloons have been Thermoplastics. Practically all compression
used as fillers to make low-density parts. Such molding uses thennosetting plastics. But in cer-
micro-balloon-filled compounds, when molded, tain &pecialized applicat!ops, thennoplastic
often are tenned "syntactic foam," achieving materials may be processed by compression
densities as low as 0.78 g/cc. molding.
Other resin systems include melamine-for- These materials, when compression-molded,
maldehyde (often used in plastic dinnerware), become plastic under pressure and heat in a
urea-fonnaldehyde (common in white or pastel heated mold and flow out to the contour of the
heat-resistant handles for kitchenware, or out- cavity. Molds must be arranged for rapid heat-
let sockets for household use), alkyds and ing and cooling because the molded articles
polyesters (often used in high voltage insula- cannot be removed from the mold until the ma-
tors in TV sets, or for arc resistance and insu- terial has been sufficiently cooled to harden.
lation in circuit breakers and switch gear), di- This process of softening the plastic by heating
allyl phthalate (electrical connectors in com- and hardening it by chilling can be repeated in-
puters), epoxy (housings for electronic com- definitely.
ponents), and silicone (high-temperature re- Large plastic optical lenses, for example,
quirements to 600 0 P or more). Common fillers may be compression-molded from methyl
include silica, glass, wood flour, natural or methacrylate (acrylic). In this particular in-
synthetic fibers, and combinations of these. stance, using compression molding rather than
Although most thennosetting fonnulations the nonnal injection molding helps eliminate
are dry and granular at room temperature, some flow marks, warpage, and shrink marks.
are puttylike, some in the fonn of dry or moist Por molding articles of heavy cross section
matted fibers, and some a fine powder. from thennoplastics (e.g., toilet seats), a com-
When subjected to heat, thennosetting for- bination of injection and compression is some-
mulations first become liquid and then undergo times advantageous. The mold is filled with hot
an irreversible chemical reaction called cure or softened material by injection, and then is sub-
polymerization. If polymerization occurs under jected to pressure by means of a compression
 COMPRESSION AND TRANSFER MOLDING 253

force plug. This positive application of pres- The mold is closed under pressure, and with
sure during cooling minimizes the development heat and pressure, the material softens, filling
of voids and shrink marks. out the contours of the cavity created by the
two halves of the mold.
The molding powder may be volumetrically
Molding of Phenol-Formaldehyde fed, weighed out, or shaped into preforms. The
Compounds charge may be fed as cold powder, or pre-
heated. It can be preheated by radio frequency,
The details of the procedure of molding ther- infrared, an oven, or other methods of heating.
mosetting materials can be conveniently cov- Preheating shortens cure time, reduces the
ered by a description of the molding of phenol- molding pressure required, minimizes erosion
formaldehyde compounds. The minor differ- and abrasion on mold cavity surfaces, and im-
ences in procedure required by other thermo- proves electrical properties.
setting materials will be discussed in later sec- Compression molding conditions generally
tions. fall in the following ranges:
A typical mold is made in two parts, which,
when brought together, enclose a cavity rep- Temperature: 300-400°F (340°F typical)
resenting the article to be molded. The two Pressure: 2000-10,000 psi on part (3,000 psi
parts are mounted in register, in a hydraulic, typical)
pneumatic, or mechanical press, which serves Cure time: 30-300 seconds (90 seconds typ-
to open and close the mold and to apply pres- ical)
sure to its contents.
The most common method of heating molds For most molded articles, the plastic mate-
for compression molding today uses electrical rial must be confined during molding by tele-
heating cartridges or strips. Electrical heating scoping one half of the mold into the other half.
gives good results with molds that have a uni- A slight clearance is allowed between the
form distribution of heating elements with ad- halves in order to permit a slight excess of
equate capacity. It has the advantages of high molding compound to escape; usually a clear-
efficiency, is clean and simple to hook up, is ance of 0.001 to 0.005 inch is sufficient. The
easily adjustable to 400°F, and, with modem material filling the cavity is held under heat and
temperature controllers, is accurate and reli- pressure to harden it, and then the mold is
able. opened and the molded article removed. Ther-
Steam molding, popular in the past, has de- mosetting materials, having been hardened by
clined in recent years, partly because of the dif- a chemical change caused by the heat, can be
ficulty of producing the higher pressures needed ejected after the proper curing cycle with no
to reach the not uncommon 350°F and higher cooling of the mold.
mold temperatures. With steam, the mold must Usually, articles requiring special dimen-
be cored or channeled for circulation of steam sional control can be removed hot from the
under pressure. However, steam is useful in heated mold and placed on a suitable fixture
large, complicated molds because it automati- that holds them during cooling and prevents
cally replaces itself as it condenses and holds distortion.
the mold at an even temperature. The polymerization reaction of phenolics re-
Molds occasionally are heated by other me- leases water vapor and traces of other gases
dia such as oil, hot water, and gas flame. How- such as ammonia. For parts with section thick-
ever, such media are limited in their usefulness k
nesses of inch or more, gassing or breathing
because they lack the latitude and adaptability the mold may be necessary in compression
of steam and electricity. molding of phenolic. The procedure followed
Phenolic compression molding is carried out is to release the pressure on the mold either just
by inserting a predetermined amount of mate- before or after it has closed on the material
rial into the lower half of the mold (Fig. 9-1). charge. The mold should be opened just far
254 SPI PLASTICS ENGINEERING HANDBOOK

enough to allow entrapped air and gas to escape

from each cavity. Certain molding compounds
and/or molded articles require a timed "dwell"
in this open position before the mold is closed
again. And, on rare occasions, two complete
breathe cycles are required for optimum results
from a given mold. Gassing or breathing of the
mold will result in denser moldings, reduce the
chances of internal voids or blisters, and
shorten the molding cycle.
The proper molding procedure produces
cured articles of sound, uniform structure.
There is usually some excess cured material at
the parting line, still adhering to the molded
part. This "flash" must be removed by hand
operation, tumbling, or blasting with a mild
abrasive, or finished as described in Chapter 23.
General-purpose phenolic molding com-
pounds are supplied in granular form, and can
be loaded into the mold in this form in weighed Fig. 9-2. An automatic preformer, 20 tons pressing
or measured charges. But in commercial semi- capacity, with hydraulic power pack, for compacting cold
thermosetting granular compounds to produce preset
automatic operations there is economy in pre-
uniform weight preforms for compression or transfer
forming such material into tablets of the correct molding . (Courtesy Hull Corp.)
size and weight by means of automatic pre-
forming equipment. This is less expensive than
weighing out the individual charges; the tablets The practical benefits include better surface fin-
are easily handled and can be loaded into the ish, freedom from flow marks, better uniform-
cavity conveniently, either manually or by ity of cure, and less difficulty in production of
means of a loading board. Frequently, through articles of thick section, as well as the economy
the use of preforms the cavity loading chamber of shorter cure cycles, and the prolonged life
of the lower half of the mold can be made less of the cavity because of reduced surface wear.
deep than it would have to be in order to hold Metal parts, or inserts, placed in the mold
the charge in the bulkier form of looser gran- and held firmly in position, can be molded into
ules. (See Fig. 9-2.) the article. (See Chapter 25.)
A few high-impact phenolic molding mate-
rials, which contain fabric or fibers as re- Molding of Urea-Formaldehyde and
inforcement for the molded article, can be Melamine-Formaldehyde Compounds
preformed automatically only in specially con-
structed preformers with stuffing mechanisms. The techniques employed in handling and
In many facilities they are loaded as weighed molding urea-formaldehyde and melamine-for-
charges or preformed by hand. maldehyde are, in general, similar to those used
All plastics require heat in order to be for phenol-formaldehyde, but some differences
molded. Because of their inherently poor ther- in practice frequently are required.
mal conductivity, the penetration of heat from As these are usually light-colored materials,
the hot mold into the cold material is slow, and in contrast to the typical browns and blacks of
it may not be uniform. Time is saved, and uni- phenolics, attention must be directed to pre-
formity is promoted, by preheating the plastic venting any contamination that will show up in
before it is put into the mold. This converts the the molded article. Dust from adjacent presses,
plastic into a uniformly softened mass, ready the soiling of preforms, and incomplete re-
to flow cleanly and evenly as the mold closes . moval of flash from the mold are frequent
 COMPRESSION AND TRANSFER MOLDING 255

sources of contamination. By making the nec- The design of the molded article is facilitated
essary provisions to prevent contamination, by the fact that variations in wall thickness
urea and melamine can be run with a low per- cause no trouble. Materials can be preheated to
centage of rejection for dirt. 250°F and molded at regular temperatures of
In molding urea and melamine, the design of 315°F with no danger of discoloration. The du-
the article and of the mold is particularly im- ration of cure is equal to or less than that of
portant because the translucency and light color phenolic compounds.
of these plastics fail to conceal flow marks and Low pressure, glass-filled polyester molding
gas pockets such as may be present but unde- compounds can be molded satisfactorily in reg-
tected in the dark, opaque phenolic materials, ular compression equipment if the molds have
Hence it is desirable, whenever possible, to de- adequate restriction to ensure filling out. Also,
sign both the article and the mold to minimize adequate vents are needed because the polyes-
such defects in appearance. Ribs, variations in ters effectively seal air in blind holes in molds,
thickness, louvers, and molded holes can be with resulting porosity in the molded article.
molded satisfactorily in urea when the article In most cases, the actual molding cycle in-
and the mold are properly designed. volves simply loading the mold, closing the
In molding these materials, it frequently is press, degassing (although that is less often re-
necessary to open the mold slightly and briefly, quired for polyesters than for conventional for-
after it has been initially closed, to allow the maldehydes), and completing the cure. How-
escape of gas formed in the reaction of curing. ever, there are applications that require more
Melamine and urea materials generate moisture elaborate techniques, such as a slow close or a
under the heat of molding. Also, they entrap dwell period, to give the best results. In such
and effectively seal air during their compres- cases, no overall rule may be prescribed; the
sion from an initially high bulk down to one- cycle must be worked out for each job.
half or less volume in molded form. Figures 9-3 and 9-4 show two types of
Both urea and melamine sometimes may be presses used for compression molding.
preheated advantageously before being put into
the mold. Melamine-formaldehyde may be
electronically preheated successfully, but urea Molding of Alkyd Materials
does not react so well to electronic methods.
The techniques of molding alkyd thermosetting
For urea, heating by conduction, such as in a
materials are similar to the above, except that
rotary-canister preheater or, for automatic
presses, in an oil-bath heater, has gained more the chemical reaction is usually much faster for
alkyds, so that faster-closing and -opening
favor. Infrared lamps also have been used with
presses are required. In molding these mate-
some success. The mold temperature for urea
rials, it frequently is necessary to breathe or de-
materials is usually 325°F or less.
gas the mold slightly and briefly, after it has
been initially closed, to allow the escape of gas
Molding of General-Purpose Polyester formed in the reaction of curing.
Molding Compounds

A line of general-purpose polyester molding Molding of Thermoplastic Materials

compounds is available in pastel shades having
excellent high stability. These materials have The general procedure for thermoplastic mate-
an outstanding characteristic in that there is lit- rials is the same as for thermosetting materials,
tle or no "after-mold shrinkage." This makes but the molded article is hardened under pres-
them desirable for electrical household appli- sure by cooling in the mold (i.e., by shutting
ance applications, especially when used in con- off the steam and circulating cold water through
nection with metal inserts. the coring of the mold). Some experimentation
These polyester materials can be readily will be necessary to establish at what point in
molded in either transfer or compression molds. the cycle the cooling should begin and how long
256 SPI PLASTICS ENGINEERING HANDBOOK

Fig. 9-4. An upward-pressing combination transfer or

compression press, 140-ton clamping capacity, console-
style, with microprocessor cycle controls for semiautomatic
Fig. 9-3. A down-acting compression press, 400 tons operation. (Courtesy Hull Corp. )
clamping capacity , with self-contained power pack
mounted on press head. Control system includes
microprocessor and keyboard with CRT to provide and compression molds . Hand- or bench-type molds
store information for an Allen Bradley PLC2 controller. usually are preferable. Separate platen presses
All press positions are sensed by an electronic feedback are used, one electrically heated and one water-
device. The control includes both velocity and pressure
profiling of the clamp movement to ensure optimum part cooled. The mold is heated, and the shaping of
quality. especially with sheet molding compounds. the article is accomplished in the hot press; then
(Courtesy C. A. Law/on Company) the mold is quickly transferred to the cold press,
to chill the article, under pressure , so that it can
be removed.
it must be continued in order to harden the ar- Tetrafluoroethylene resin (TFE-fluorocarbon
ticle sufficiently . resin) does not soften and flow in the manner
Thermoplastic molding compounds usually of conventional thermoplastics, and it is molded
cannot be preformed. by a special technique, as follows:

Molding of Fluorocarbons 1. The granular material is preformed at

room temperature by a pressure of 2000
These materials are classed as thermoplastics, to 10,000 psi.
but are not fully amenable to the conventional 2. The preform is sintered into a continuous
technique of compression molding. gel by exposure to a temperature of about
Chlorotrifluoroethy lene (CTFE-fluorocar- 700 to 740°F in an oven or a fluid bath.
bon resin) requires mold temperatures in the 3. The piece then is given its final shape by
range of 450 to 600°F. The necessity of alter- a pressure of 1000 to 20,000 psi in a con-
nately heating to so high a temperature and fining die cavity, in which it is cooled.
cooling, makes for long cycles and large power This final step, of which there are several
consumption in conventional integrally heated variants (cold-coining, hobbing, hot-
 COMPRESSION AND TRANSFER MOLDING 257

coining), depending on the shape of the Compression molding of thermosetting ma-

article and the dimensional accuracy re- terials has certain advantages over transfer or
quired, may be omitted with articles of injection molding, as follows:
thin section for which accuracy is not im-
portant. 1. Waste of material in the form of sprue,
runners, and transfer-culls is avoided, and
Fluorinated ethylene-propylene resin (FEP- there is no problem of gate erosion.
fluorocarbon resin) can be molded into simple 2. Internal stress in the molded article is
shapes by an essentially conventional compres- minimized by the shorter and multidirec-
sion-molding technique, with gradual applica- tional flow of the material under pressure
tion of pressure up to about 1500 psi. For rapid in the mold cavity. In the case of high-
molding, a temperature of 650 to 700°F is re- impact types with reinforcing fibers,
quired, but a 3-mil sheet of aluminum must be maximum impact strength is gained. This
interposed to prevent sticking to the surface of results because reinforcing fibers are not
the mold. When this is undesirable, the mold- broken up as they are when forced
ing can be done at 550 to 600°F, but more time through runners and gates in transfer and
will be required. injection molding, and because fibers are
more randomly positioned, as compared
Cold Molding to the more oriented fibers resulting from
flow into transfer or injection molds.
Some materials are formed in presses with un- 3. A maximum number of cavities can be
heated molds, giving a very fragile molding. used in a given mold base without regard
When sintered or baked in ovens at appropriate to demands of a sprue and runner system.
temperatures, the material hardens or fuses. 4. Compression molding is readily adapta-
After cooling, the part is relatively strong and ble to automatic loading of material and
ready for use. The process is called cold mold- automatic removal of molded articles.
ing. Automatic molding is widely used for
This technique is used to make certain types small items such as wiring device parts
of ceramic insulators. The molding compound and closures.
may be ceramic powder with perhaps 15 % phe- 5. This technique is useful for thin wall parts
nolic resin by weight, homogeneously mixed. that must not warp and must retain di-
The cold pressing compacts the mixture. Sub- mensions. Parts with wall thicknesses as
sequent heating cures the phenolic, which binds thin as 0.025 inch are molded; however,
the ceramic particles together. a minimum wall thickness of 0.060 inch
usually is recommended because ther-
Advantages of Compression Molding mosetting materials are brittle as com-
pared to more resilient thermoplastics.
Thermosetting and thermoplastic materials can 6. For parts weighing more than 3 pounds,
be compression-molded. Quantity production compression molding is recommended
is possible through the use of multiple-cavity because transfer or screw injection equip-
molds, and, when production volume warrants, ment would be more expensive for larger
in fully-automatic presses, which feed metered parts.
charges of granular material into each cavity 7. For high-impact, fluffy materials, com-
and remove finished molded parts and initiate pression molding normally is recom-
the next cycle, all automatically. Large hous- mended because of the difficulty in feed-
ings (e.g., for computers, switch bases, furni- ing the molding compound from a hopper
ture drawers, etc.) are commonly compression- to the press or preformer.
molded. The size of the article that can be 8. In general, compression molds usually are
molded is limited only by the tonnage and size less expensive to build than transfer or in-
of available press equipment. jection types.
258 SPI PLASTICS ENGINEERING HANDBOOK

Limitations of Compression Molding faces, or land areas, for the molds be cleaned
between successive shots. Also slight fins or
In the case of very intricately designed articles flash must be expected on molded articles
containing undercuts, side draws, and small where the mold sections meet.
holes, the compression method may not be Another important consideration is the plas-
practicable, because of the need for compli- tics' degree of rigidity at that point of final cure
cated molds and the possibility of distorting or when ejection is to take place. Melamines are
breaking mold pins during the flow of the ma- very hard and rigid, phenolics more flexible,
terial under high pressure. Articles of 0.35 inch and unreinforced polyesters quite weak. Thus,
or more thickness may be more advantageously a compression mold for phenolic may work
made by transfer molding, particularly a thick with undrafted or even moderately undercut
article of small area, in which there is little cores. With melamines, the same mold would
flow. Thus, for a heavy handle, compression require enormous pressure to open, and would
molding would be slower than transfer or in- probably crack the molded articles at the un-
jection because in transfer the plastic is thor- dercut. Polyester articles require very careful
oughly heated and is precompressed almost to adherence to all rules for draft; they also re-
its final density prior to entering the mold. quire generous ejector pin areas to avoid frac-
Frequently, insufficient consideration is ture where the ejector pins push against the
given to the physical condition of thermoset- molded part.
ting plastics at various stages of molding. The In some cases, compression molding of ther-
complete filling of a compression mold cavity mosetting material may be unsatisfactory for
is spoken of as resulting from the flow of the production of articles· having extremely close
plastic, but because of its extremely high vis- dimensional tolerances, especially in multiple-
cosity, the plastic must be mechanically forced cavity molds and particularly in relation to non-
to fill all parts of the cavity. To ensure com- uniformity of thickness at the parting line of the
plete filling, most articles to be molded require molded article. In such cases, transfer or injec-
that two parts of the mold fit telescopically into tion molding is recommended. For a further
each other to prevent escape of plastic prior to discussion of this method of molding see be-
the final closing of the mold. Such molds are low, section on "Transfer Molding," as well
designated as fully positive (see Fig. 9-1). as Chapter 8.
Also, in order to ensure complete filling out of
the mold, it may be necessary to place the
charge of plastic into an optimum position in Procedure for Compression Molding
the mold, and in some cases to use preforms of
special shape. This is particularly important if The sequence of operations constituting the
the mold does not provide a means of confining molding cycle is as follows:
the charge. Polyester and alkyd compounds are
particularly troublesome, and require positive 1. Open the mold.
means of confinement in order to fill the cavity 2. Eject the molded article(s).
completely. 3. Place article in shrink or cooling fixtures
All thermosets, during their period of flow when necessary to maintain close dimen-
in· a mold, have an apparent surface viscosity sional tolerances (if necessary).
that is so low that clearances between mold 4. Remove all foreign matter and flash from
parts, even when held to less than one thou- the mold, usually by air blast.
sandth of an inch, become filled with plastic. 5. Place inserts or other loose mold parts, if
This often results in damage to the mold if ad- any.
equate escape is not provided for this leakage. 6. Load molding compound (powder or pre-
Overflow vents thus are provided for a re- forms, cold or preheated).
stricted escape, making the mold a semiposi- 7. Close the heated mold (breathe if neces-
tive type. It also is necessary that mating sur- sary).
 COMPRESSION AND TRANSFER MOLDING 259

8a. For thermosetting materials, hold under 5. Surface condition of mold cavity and
heat and pressure until cure is completed. force:
Certain materials require cooling under (a) Highly polished chrome-plated sur-
pressure for best control of dimensions. face.
8b. For thermoplastic materials, hold under (b) Polished steel.
pressure, while cooling to harden the ar- (c) Poor polish (chromium plating worn;
ticle. pits, gouges, and nicks).

The temperature of the mold and the pres-

sure applied are extremely important, and it is Molding pressures required for most ther-
advisable to follow the recommendations of the mosetting materials follow the pattern estab-
manufacturer for each grade of material used. lished for phenolic materials.
Thermosetting materials used in compres- Conventional phenolic materials loaded at
sion molding can be classified as conventional room temperature (i.e., without preheating) re-
and low-pressure materials (the latter should not quire a minimum pressure of 3000 psi on the
be confused with materials used in low-pres- projected land area for the first inch of depth of
sure molding of impregnated laminates). the molded article, plus 700 psi for each addi-
There are five very important variables in the tional inch of depth. Efficient high-frequency
compression molding of thermosetting mate- preheating, however, may reduce the required
rials, which determine the pressure required to pressure to as low at 1000 psi on the projected
produce the best molding in the shortest length land area, plus 250 psi for each additional inch
of time. They are as follows: of depth. The pressure required on high-impact
materials may reach 10,000 to 12,000 psi.
I. Design of the article to be produced: These recommendations of pressure are predi-
(a) Projected area and depth. cated on minimum press-closing speeds of 1
(b) Wall thickness. in) sec. The flow characteristics of thermoset-
(c) Obstruction to vertical flow (such as ting molding materials are changing contin-
pins, louvers, and sharp comers). ually during the molding, and the effect of this
2. Speed of press in closing: change is particularly noticeable in slow-clos-
(a) Use of slow- or fast-acting self-con- ing presses.
tained press. Low-pressure phenolic molding materials, ef-
(b) Use of fast-acting press served by hy- ficiently preheated by high frequency, require
draulic line accumulator system. a minimum of 350 psi on the projected mold
(c) Capacity of accumulator to maintain area, plus about 100 psi for each additional inch
constant follow-up of pressure on of depth.
material. Table 9-1 may be used as a guide for the
3. Plasticity of material: pressure required for the depth of a given
(a) Degree and type of preheating. molded article. The wide range of pressures
(b) Density of charge (preform or pow- given in the second column is necessary to
der). cover the variety of molded pieces and the types
(c) Position of charge in cavity. of press equipment used. For example, an ar-
(d) Mobility of resin under pressure. ticle of comparatively small area and great
(e) Type and concentration (usually ex- depth requires pressures at the lower end of the
pressed as percentage by weight) of range given; an article of large area and great
filler (wood flour, cotton flock, ma- depth may require pressure at the upper end of
cerated fabric, asbestos, glass or the range. Also, the wall thickness of the arti-
mica). cle influences the pressure required; thin sec-
4. Overall temperature of mold: tions require more pressure than heavier sec-
(a) Temperature variations within cavity tions. For articles involving a deep draw, fast-
and force of mold. closing presses with speeds of over 20 in. / min.
260 SPI PLASTICS ENGINEERING HANDBOOK

Table 9-1. Pressure table; pressure, psi, of projected land area.

Conventional Phenolic Low-Pressure Phenolic
Depth of
, " , , Preheated "
Molding Preheated by Not by high Not
(in.) high freq uency preheated frequency preheated

O-x 1000-2000 3000 350 1000

X-IX 1250-2500 3700 450 1250
2 1500-3000 4400 550 1500
3 1750-3500 5100 650 1750
4 2000-4000 5800 750 2000
5 2250-4500 * 850 **
6 2500-5000 * 950 **
7 2750-5500 * 1050 **
8 3000-6000 * 1150 **
9 3250-6500 * 1250 **
10 3500-7000 * 1350 **
12 4000-8000 * 1450 **
14 4500-9000 * 1550 **
16 5000-10000 * 1650 **
* Add 700 psi for each additional inch of depth; but beyond 4 in. in depth it is
desirable (and beyond 12 in. essential) to preheat .
.. Add 250 psi for each additional inch of depth; but beyond 4 in. in depth it is
desirable (and beyond 12 in. essential) to preheat

for full depth of draw will make it possible to These molds usually are small and light and
use lower pressures. contain no more than a few mold cavities. They
The time required to harden thermosetting usually are heated by means of electrically
materials commonly is referred to as the cure heated or steam-heated platens attached to the
time. Depending upon the type of material, press. (See Fig. 9-3.)
preheat temperature, and thickness of the Semiautomatic molds are self-contained units
molded articles, the time may range from sec- that are firmly mounted on the top and bottom
onds to several minutes. platens of the press. The operation of the press
opens and closes the mold and also operates the
Types of Compression Molds ejector mechanism provided for the removal of
the molded piece from the cavity or cavities.
For most economical production, mold cavities This type is employed particularly for multiple-
are made from high-grade tool steels so that cavity work and for relatively long production
they can be hardened and polished. Through- runs, or for articles too large or too deep in
hardening, to about Rockwell C56 to C58 is draw for hand molding. The use of ejector pins
preferred to case-hardened steels, for a long calls for careful consideration in the design of
mold life. the heating provision in the mold, to ensure that
A hand mold is so constructed that it must there is no interference between ejector pins and
be removed from the press manually, following the electric heating cartridges of the steam
each cycle, taken apart to remove the molded channels.
article, and assembled again with the molding Fully automatic molds are of a special design
material charge placed in the cavity (cavities), and adapted to a completely automatic press.
for the next molding cycle. These molds are The complete cycle of operation, including the
used primarily for experimental or for small loading and unloading of the mold; is carried
production runs, or for molding articles that, out automatically. A multiple-cavity mold may
by reason of their complexity, require disman- be used, and usually the molded article con-
tling of mold sections in order to release them. tains no insert or metal part.
 COMPRESSION AND TRANSFER MOLDING 261

Machinery and Equipment is often held reasonably constant by keeping the

mold halves on heated surfaces during the time
Presses. Presses for hand molds range from when they are outside the press heating platens.
small laboratory presses to production equip- Heat for automatic and semiautomatic molds
ment of clamping capacities from 5 to 100 tons. may be supplied by steam flowing through
The heating plates are fastened directly to the channeled mold sections or by electric heaters
top and bottom press platens. The mold is installed in the platens of the mold or press.
placed between these plates for the transfer of For chilling thermoplastics, a supply of cold
heat and pressure to it during the molding op- water is required, which flows through cooling
eration. Presses for semiautomatic molds range channels in the mold, or the hot oil circulating
in size from 10 to 4000 tons and up. These system is arranged for chilling as well as heat-
presses have top and bottom platens with grids ing.
and parallels so that the molds can be readily
mounted. The presses are provided with either Automatic Compression Molding
mechanical or hydraulic ejecting apparatus to
remove molded articles from the molds. Description. Fully automatic compression
In compression molding articles with high molding involves the automatic sequencing of
vertical walls, it is important that the pressure necessary functions performed in making fin-
be applied sufficiently fast to maintain maxi- ished molded articles from granulated or nod-
mum pressure on the material as it becomes soft ular thermosetting molding compounds. In es-
and flows within the mold cavity. Straight ram sence, it involves a compression-molding press
hydraulic presses, as opposed to hydraulic tog- equipped with a mold and additional equipment
gle-type presses, are considered best for arti- designed (1) to store a quantity of molding
cles with high vertical walls. compound; (2) to meter, volumetrically or
Self-contained hydraulic press units must gravimetrically, exact charges of compound;
have a pump capacity large enough and must (3) to deposit these charges into appropriate
be fast enough to take full advantage of the mold cavities; (4) to remove the finished article
short period of maximum plasticity. from the mold area following each cycle; and
(5) to remove any flash or granular molding
Hydraulic System. Hydraulic presses may be material not ejected with the finished article,
provided power, or a group of presses may be usually by means of an air blast from appro-
operated from a single line. A hydraulic pump priately positioned nozzles. With reference to
provides the necessary volume of oil or (rarely) (2) and (3) above, many automatic compres-
water at the required pressure, and an accu- sion presses also preheat the charge by infrared
mulator maintains a reserve sufficient to serve or high frequency heating just prior to filling
all presses on the line without fluctuation of the cavities. Once an automatic press has been
pressure. put into operation, it can run unattended except
In some cases, a high- and low-pressure ac- for periodic recharging of the storage container
cumulator system is used for economy. The (hopper) and removal of finished moldings,
low-pressure system is especially advantageous plus an occasional adjustment in the control
for operating presses with a long stroke; the system to accommodate minor variations in the
low-pressure system can advance the moving compound, ambient temperature, and humid-
part of the mold up to the point where the ma- ity.
terial takes pressure, and then the high pressure Automatic compression molding has been
is valved in to complete the molding cycle. done for many years. Many basic improve-
ments in some of the earlier types have led to
Heating and Cooling of Molds. A hand mold faster operations, better-molded products, and
is heated and cooled by contact with cored plat- more economical production. Molders gener-
ens mounted in the press, and its temperature ally believe that automatic molding will expand
262 SPI PLASTICS ENGINEERING HANDBOOK

many times over in years to come. Although termine when fully automatic molding is fea-
screw-injection molding of thermosetting com- sible.
pounds (see Chapter 8) is gaining in usage and On the other hand, automatic molding may
popularity, automatic compression molding not be feasible if the article to be molded is
continues to prove ideal for many applications, subject to one or more design changes early in
and to playa major role in thermoset molding. the life of the mold. Even this consideration is
altered if the fully automatic mold has, say,
Applicability. Probably the main reason for four cavities, and the semiautomatic mold has
selecting automatic compression molding is the eight cavities.
need to produce a large quantity of an article. Automatic molding generally is not feasible
An automatic press involves heavier financial if the molded article must be made from mold-
investment than a manual or semiautomatic ing compounds with a bulk factor in excess of
unit, and the full setup, including metering ad- 3 (except in the case of certain nodular molding
justment and alignment of the comb that re- compounds) or with poor dry flowing proper-
moves articles from the mold, may take longer ties in feeding devices, or in parts requiring
for automatic molding than for semiautomatic molded-in inserts.
molding. These extra costs may be offset in a
long production run by a high rate of produc-
tion, a small number of rejects, and a sharp re- Basic Requirements for Automatic
duction in labor costs. Contrary to general be- Compression Molding
lief, a mold for an automatic press often is no
more expensive than a good semiautomatic Design of Molded Article. For automatic
mold because both must be precisely machined compression molding, considerable attention
and have essentially the same arrangement of must be given to the design of the molded ar-
knockout pin, hold-down pin, and so on. In ticle. Articles 3 inches or more in height may
fact, an automatic mold usually requires fewer require daylight, platen stroke, or ejector pin
cavities than a semiautomatic mold to achieve stroke that exceeds the specifications of auto-
a given production rate, and may therefore be matic presses now available. The need to keep
less expensive . such deep cavities free from flash or impurities
. For preliminary analysis of a particular also may make trouble-free operation difficult.
molding requirement, the difference in cost be- Articles of particularly fragile sections, or
tween semiautomatic and fully automatic requiring fragile mold pins or mold sections,
molding may be calculated on the basis of la- generally are not practicable for trouble-free
bor. For example, semiautomatic operation automatic molding. The molded article should
may cost several dollars more per hour than be free of sharp changes in· section, and should
fully automatic molding, because one operator have adequate draft (1 or more) to facilitate
0

is used for one or possibly two presses in semi- ready removal from cavity or force. Such a
automatic molding, whereas one person only is draft simplifies the manufacture of molds and
needed to monitor as many as eight fully au- helps to minimize their wear.
tomatic machines. Other factors may include a Articles normally requiring molded-in in-
higher production rate, less wastage of raw ma- serts should be studied to determine the possi-
terial, fewer rejects, and less downtime. Not to bility of molding them without inserts and put-
be overlooked is the fact that production rates ting the inserts in as a secondary operation. The
in automatic molding often can be geared to the shorter cycles possible with this method gen-
demand requirements of the molded article; in- erally result in an overall cost saving. Some ar-
ventories of the molded article thus may be re- ticles that normally require side cores or a split
stricted, with additional savings. mold should be evaluated to determine whether
Intelligent analysis of the various cost fac- a redesign is possible, or whether two plastic
tors given above will enable the molder to de- parts, both molded automatically, might be
 COMPRESSION AND TRANSFER MOLDING 263

substituted for the one article and still prove tual cavities and forces and land areas generally
more economical in the long run. The best re- is recommended, and all sharp edges or comers
sults are obtained when the designer is thor- should be rounded wherever possible, to min-
oughly familiar with the techniques possible in imize accumulation of flash.
automatic molding, the techniques used by the Today, with miniaturization, small molded
moldmaker, and the functional requirements of articles frequently are necessary. In automatic
the final application of the article. molds for small articles, subcavity design fre-
quently is the most satisfactory solution. A
Mold Design. The design of a mold for au- number of the small cavities are arranged in a
tomatic molding incorporates most of the fea- subcavity, which receives one charge of mold-
tures used in manual or semiautomatic mold- ing compound in each cycle. The complete
ing, but two major features require special cluster of molded pieces remains intact during
attention. First, the molded article must be ejection, being held together by flash of con-
made to withdraw with the same half of the trolled thickness. Articles smaller than about 4
mold, either top half or bottom half, on every inch in diameter usually should be molded in
opening stroke. If, for example, bottom ejec- this way.
tion is required, every precaution must be taken
that the molded piece will not stick to the top Selection of Molding Compound. In addi-
half of the mold on the opening stroke. Under- tion to the above requisites, consideration must
cuts, or ridges to grip the article, are frequently be given to the automatic metering of molding
required. Top hold-down pins are often used. compound. Generally speaking, automatic
These are essentially the same as knockout molding requires materials that flow easily in
pins, but are designed to push the molded piece the dry state and do not tend to cake or bridge
away from the top half of the mold as it is when in storage or when required to flow
opened, to ensure that the piece remains in the through feeder tubes. Bulk factors generally
bottom half of the mold. Similarly, bottom must be under 3.0, and sometimes the finer
hold-up pins are used where top ejection is re- powders and coarser granules must be re-
quired. The design of the article indicates moved. The limitations on molding compounds
whether top ejection or bottom ejection is pref- develop not so much because of the molding
erable. In automatic operation, the molded ar- operation itself, but because of the problems
ticle must be under positive control at all times. involved in automatic feeding. Manufacturers
Automatic takeoff devices and scanning or of molding compounds have recognized this
checking devices are set to confonn with a sit- problem and have produced standard materials
uation that must remain essentially unchanged that provide excellent pourability for volumet-
from cycle to cycle. ric feeding in automatic compression presses.
The second essential design feature is to en- They also are able to give specific advice on
sure that any flash will cling to the molded materials that can be used and will produce the
piece, and not to the mold face or cavity or best quality in the finished molded article.
force. Automatic presses generally utilize an air Some automatic molding presses utilize vi-
blast as a cleaning device to remove flash or brators or agitators in the hopper to minimize
excess powder from a mold just prior to load- caking or bridging.
ing the new charge of material. But such an air-
blast mechanism is never so thorough as an op- Equipment Available. Several different types
erator in ensuring that the mold is clean. Thus, of automatic molding presses are available,
every effort must be made to keep flash to a some of which have been in use for as long as
minimum, and to be sure that any flash that 40 years or more. The conventional equipment
does develop is automatically removed with the is of the vertical type, with the platen moving
molded article. In the mold, well-polished sur- either up or down during the compression
faces are necessary, chrome plating of the ac- stroke. As the press opens following each
264 SPI PLASTICS ENGINEERING HANDBOOK

cycle, the molded pieces are stripped from the molded pieces must be approximately the same
knockout pins by means of a comb or an air size.
blast; following this operation, the loading Some of the advantages of rotary presses are
board moves over the mold to drop charges into listed below:
the cavities. The loading board then leaves the
mold area, and the press closes for its next 1. Individual caVIties are easy to change,
cycle. Operation generally is of a sequential thus reducing loss of production time.
nature, wherein each individual operation, 2. Some presses can incorporate molds of
when completed, initiates the next step. Con- different volumes, as the material feed
trols generally are electrically actuated, and use can be varied for individual cavities.
pneumatic, hydraulic, or mechanical means to 3. High productivity can be gained with a
position the takeoff comb and loading board and minimum amount of labor.
other moving parts. Some smaller presses de- 4. Rotaries are especially adaptable to high-
part from sequential-type operation and remove volume, small parts such as wiring de-
the molded articles and load the new charge of vices and closures.
powder simultaneously. 5. When different-size cavities are used in
Another type of automatic press is the rotary one press, molding cycles are determined
press. As the name implies, these presses have by the part with the heaviest section.
a rotary movement of the main moving parts. 6. The variable speed of rotation controls the
In one type, a number of single-cavity molds length of cure.
are arranged in a large circle, the lower halves 7. Unloading mechanisms can be used (e.g.,
affixed to one platen and the upper halves to wheel to unscrew molded threaded caps,
another platen. Generally speaking, these plat- air jet, stripper plates, knockout pins,
ens do not move in relation to one another. A twist ram).
traveling mechanism moves continuously 8. Cavities do not have to be precisely
around these two platens at a controlled speed. matched for applied pressure.
This mechanism performs, in the appropriate
sequence, the functions of causing two individ- Several limitations to the rotary press are as
ual mold halves to come together and to remain follows:
together while the mechanism completes essen-
tially 300 0 of travel around the platen. The 1. Inserts cannot be loaded easily.
moving mechanism causes the mold to open, 2. Part size usually is limited to small parts
the molded pieces to be physically ejected and and is governed by the pressure available
the force and cavities to be cleaned by an air to each station. The mold load is usually
blast, a new metered charge to be dropped into in the range of 2 to 5 tons, with some
the cavity, and the mold halves to close again. machines as high as 15 tons.
Each mold thus is actuated individually and at 3. Molds must be of the flash or semiposi-
a uniform sequence after each preceding mold. tive type. Complicated molds with fea-
There may be 10 stations, or even 30 stations, tures such as split cavities, cores, or side
on a rotary press ofthis type. The cavities may draws cannot be readily adapted.
all be alike, or they may differ, but the cure
times of each must be compatible with the oth- Types of Machines
ers, as the overall cycle is dependent on the
time required for one complete rotation of the Several commercially available automatic
moving mechanism. molding presses are shown in Figs. 9-5, 9-6,
Also, rotary presses are made in which the and 9-7. In selecting the equipment for a spe-
"mechanism" remains stationary and the round cific job, the different characteristics of the var-
platens with the molds rotate about a central ious presses should be studied to ensure that the
axis. In operation, however, the principle is the job in hand can be done safely, effectively, and
same as that described above, except that all economically. Various safety features are
 COMPRESSION AND TRANSFER MOLDING 265

Fig. 9-5. Operator positions hand transfer mold on lower heating platen prior to molding cycle. The work loading
station mounted on front of the press features temperature-controlled heated surfaces as well as a fixture for removal of
molded parts from the mold. (Courtesy Hull Corp. )

available on such presses to ensure protection Preheating in Automatic Compression

from double shots, malfunction of accessories, Molding
and so on .
To obtain the fastest cycles in automatic
compression molding, particularly when part
thickness is 0.060 inch or more, the molding
compound should be preheated prior to placing
it in the mold cavities . There are three common
methods used for such preheating.

Automatic Screw Preplasticating. This ap-

proach to preheating the molding compound
prior to depositing it into the cavity utilizes a
rotating screw inside a heated barrel, similar to
the screw and barrel mechanism used in injec-
tion molding machines . (See Fig. 9-8 .)
Machines are arranged with one, two, or
three separate screws, each with its own speed
control, water-jacket, and shot measuring de-
vice (Fig. 9-9) . Cups at the open end of the
barrel nozzle accept and compact the material ,
Fig. 9-6. A 75-ton, hydraulically actuated , fully
automatic compression molding press. Many such presses controlling the weight of the preheated charge.
lire still in use but they are no longer manufactured. At the proper sequence in the machine cycle ,
(Courtesy Stokes Div . . Penn walt Corp. ) the cups are withdrawn from the nozzles, leav-
266 SPI PLASTICS ENGINEERING HANDBOOK

Fig. 9-7. A 200-ton shuttle press for compression molding

with inserts, using automatic feeder for electronic
preheating and loading molding compound. Two bottom
halves of molds, arranged on the shuttle table, and the
simple top half of the mold enable essentially continuous
molding while the operator loads inserts in the bottom half
for the next cycle . (Courtesy Hull Corp. )

Fig. 9-8. An automatic compression press, downward

ing the preheated preform exposed (Fig. 9-10). acting, available with clamping capacities from 18 to 70
A shearing device is then actuated to cut the tons, utilizing double toggle action, material metering,
extruded material from the nozzle. A chute as- cavity loading, and molded part ejection are mechanically
sembly or a feed board located beneath the noz- interlocked and motivated by the moving press platen.
(Courtesy Glueo. Inc. )
zle moves forward to direct the preforms into
their respective cavities.
Preheating Process. The temperature of the Each is adjustable, to make preforms to any
preheated charge can be as high as 280°F, de- weight increment within its capacity. When the
pending upon the material. Heat input is ac- cup has been fully charged to its preset mea-
complished through convection from the water surement, a limit switch stops the screw rota-
jackets (110 to 130°F), and frictional heat gen- tion.
erated by forcing the material through the Cure time comparisons, shown in Fig. 9-11,
clearance between the screw tip and the nozzle reflect the extremes of part thickness. A part
wall. with a cross-section thickness of 0.070 inch
Work input at the nozzle results in a mini- cures in an average of 24 seconds when using
mum lapsed time between obtaining a high ma- cold powder of an "eight" plasticity, and in
terial temperature and depositing the charge almost 45 seconds using an "eighteen" flow.
into the mold. The same part using screw compression cures
The preform cups are designed with mini- in 12 and 15 seconds, respectively, for the same
mum and maximum material weight charges. materials.
 COMPRESSION AND TRANSFER MOLDING 267

Fig. 9-9. A tri-screw unit after preheating a charge of thennoset material. (Courtesy Stokes Div .. Penn walt Corp. )

Fig. 9-10. A tri-screw assembly with measuring cups withdrawn. (Courtesy Stokes Div .. Pennwalt Corp. )
 268 SPI PLASTICS ENGINEERING HANDBOOK

legend
1. PREHEATED FLOW 8 PHENOLIC
2. PREHEATEO FLOW 18 PHENOLIC
3. COLD POWDER FLOW 8 PHENOLIC
4. COLD POWDER FLOW 18 PHENOLIC
5. INFRARED PREHEATED GRANULAR 8 FLOW PHENOLIC

.400

.350
VI
III
J: .300
U
~
~ .250
VI
VI
III .200
z
:.:
u
:rt- .150
t-
II: .100
oct
Q.

.050 r-~---+---r--+---r-~---+---r--+---r-~---+--4---+---r-~

10 20 30 40 50 60 10 80 90 100 110 120 130 140 150

CURE TIME IN SECONDS

Fig. 9-11. Cure time comparison. (Courtesy Stokes Div., Penn walt Corp. )

A part with a cross-section thickness of .370 Then it returns to the hopper for the next charge
inch cures in an average of 150 seconds, as while the press closes for cure.
compared with 30 seconds with screw
. compression. With cold powder, even a 150- High-Frequency Preheating. High-fre-
second cure does not ensure that the part will quency (generally 70 MHz or 100 MHz) pre-
be free from internal voids. heating is accomplished by bringing the mate-
rial charge of molding compound between two
Infrared Preheating. This approach to pre- fiat plates, or electrodes, which reverse their
heating features an infrared heat source posi- electrical charge at very high frequencies . Be-
tioned between the hopper and the press, fo- cause the molecules of thermosetting molding
cused downward to the level of the powder compounds are polar (i.e ., have north and south
loading board. When the individual cavity poles), the molecules reverse their position with
charges have been deposited from the hopper each change of frequency. Such fast mechani-
to the cups in the loading board, the loading cal activity generates heat fairly uniformly
board moves toward the mold, but it pauses di- throughout the mass of compound and raises its
rectly under the infrared heat source for a time temperature from ambient to about 200°F in 10
interval of approximately the same length as the to 20 seconds, depending on the power of the
cure time set for the molding . While parts are preheater and the mass of molding compound
undergoing cure in the mold, the material in the per molding cycle.
loading cups is heated to temperatures ap- Automatic compression presses using high-
proaching 200°F. As soon as the molding cycle frequency preheating generally are equipped
has been completed, and the molded parts have with an integrated loading unit incorporating
been ejected and removed from the mold area the hopper, the powder metering mechanism,
and the mold blow-off has been accomplished, the loading board with cups, and the high-fre-
the loading board travels over the bottom mold quency generator and electrodes, with the load-
half and deposits its charge of heated material. ing board traveling over the bottom half of the
 COMPRESSION AND TRANSFER MOLDING 269

mold to deposit the preheated charges at the ap- form of transfer molding frequently is called
propriate moment in the press cycle. plunger molding.
In the most commonly used U.S. molding
presses, the main ram is attached to the lower
TRANSFER MOLDING press platen and operates upward. When these
presses are equipped for transfer molding, the
The term "transfer molding" is now generally
auxiliary rams may be mounted on the side col-
applied to the process of forming articles, in a
umns, operating at right angles to the main col-
closed mold, from a thermosetting material that
umns, operating at right angles to the main ram,
is conveyed under pressure, in a hot, plastic
or on the press head, operating downward in a
state, from an auxiliary chamber, called the
direction opposite to that of the main ram, or
transfer pot, through runners and gates into the
on the press bed or within the main ram, op-
closed cavity or cavities.
erating upward and in the same direction as the
main ram.
History The introduction of high-frequency dielec-
tric preheating during World War II greatly ac-
Prior to the development of transfer molding, celerated the growth of transfer molding, par-
thermosetting materials were handled only in ticularly with auxiliary-ram presses. Speeds of
compression molds, by methods adapted from transfer and of cure were increased, and lower
the prior art used in forming articles from rub- pressures could be used for transfer and for
ber, shellac, and cold-molded compositions. clamping the mold.
The compression method is still widely used, In 1956, two automatic transfer-molding
and is entirely suitable for the production of a machines were developed. One is a small hor-
great variety of small and large articles of rel- izontal machine, using loose powder and com-
atively simple outline and plain cross-section. paratively inexpensive molds. These and var-
However, compression molding does not ious other working parts of the machine are
readily permit the forming of articles having in- readily accessible and easily maintained. The
tricate sections, thin walls, and fragile inserts, other machine is much larger, with a 400-ton
and those on which close tolerances on "build- clamping capacity, and is extremely fast. It is
up" dimensions are desired. When compres- designed to use preheated preforms.
sion molding is applied to such articles, the In the mid-1960s, a high speed automatic
molds and maintenance usually are very costly, transfer press, with integral preforming and
because of excessive wear and breakage. high-frequency preheating, entered the market,
To overcome these difficulties, transfer and yielded fast cycles, as short as 25 seconds,
molding was introduced by Shaw Insulator for multi-pin connectors and similar parts.
Company, Irvington, New Jersey, in 1926. At The progress in molding technology and in
that time, the process was carried out in con- equipment has been matched by the develop-
ventional single-ram compression presses, with ment of improved materials, particularly the
three-piece molds, as described later. To pro- phenolics, which are better suited to the large
mote flow, it frequently was necessary to em- multiple-cavity transfer molds now in use than
ploy special, long-flow, premium molding were the special transfer materials previously
compounds, and to preheat them in an oven. employed. These materials have more rapid
This type of transfer molding usually is re- rates of flow and shorter cure times than those
ferred to as the pot type. previously available for transfer molding. With
Later, presses equipped with two or more the aid of dielectric preheating, they exhibit the
rams were developed for transfer molding. In same total flow as did the special transfer ma-
these, the main ram is attached to the lower or terials formerly required, but accomplish this
upper press platen in the usual manner, and flow in a much shorter time. Rigidity on dis-
holds the mold closed. An auxiliary ram is used charge from the mold has also been greatly im-
to force the material into the closed mold. This proved. This all has made for faster production
270 SPI PLASTICS ENGINEERING HANDBOOK

and lower molding costs, and has further en- 3. For complicated parts where tolerances
hanced the usefulness of transfer molding. are very close in three dimensions.
4. For production of various small molded
parts that are assembled together. A
Utility of Process "family" transfer or plunger mold is
As a molding technique, transfer molding of- economical, and it also permits substitu-
tion of different cavities in one mold, de-
fers the molder certain advantages. Some typ-
pending upon production requirements.
ical applications where the process is useful are
as follows: 5. In the reduction of finishing costs, be-
cause of less flash on the transfer-molded
parts.
1. For parts requiring side draw core pins
which must be readily withdrawn before Description of Process
discharging a part from the mold, and
which may have to be extended into the Essentially, this type of molding requires the
cavity after the mold is closed and before transfer of material under pressure from a
material is introduced into the cavity. "pot" or "well" through runners and gates
2. For applications where inserts must be into cavities retained in a closed heated mold
molded into intricate parts. (Figs. 9-12 and 9-13). Usually, the charge has

- CULL

SPIIUE

1
I

/fESS
(A) MlvEMCNT

TIIANSFEN PLUNGEII -
liE TAINEII PLA TE
--=~- CULL PICK UP
TRANSFER

SPRUE - --~~
- - - - - -__ __

TRANSFER TRANSFER CHAMBER

RETAINER P .. A TE
(LOADING PLA rE )
FLOATING PLATE -
PLUNGER PE TAINER
P L Are

SpRUC Bt:SHING ",.................... ):=~~--- FORCE

PART

CAVITY RCTAINER
PLATE
.....
IfNOCIfOUT P,NS - - -- " " "~ - - SPRue LOCI( PIN

(C)

Fig. 9-12. True transfer or pot-type transfer molding, the forerunner of today's common "plunger" or conventional
transfer molding. (From Plastics Mold Engineering)
 COMPRESSION AND TRANSFER MOLDING 271

- - STD. HEX.
NUT

A PLAIN
WASHER
STUD
)".,.,......7"""'h"~Et::v:>l
- SPRING

SECTION E-£

VIEW WITH TOP HALF REMOVED

8 APPROX. -
_~ TRANSFER POT

~ ~ S':LlT RING

___ CAVITY RETAINER

GUIDE 8USHING
GUIDE PIN

~~~ffintti~~== --
KNOCKOUT 8AR
t--- - - - PARALLEL (2)

- 80TTOM PLATE

'-- f SOC. HEAD

CAP SCREW {8}
SECTION A-B-C-D
Fig. 9-13. Plunger-type transfer mold.

been preheated before being placed in the pot. Thus, the wedging action of the material will
With preheating, less pressure is required for not force the mold cavities to open and flash.
transfer, and the mold cycle time and mold Pot-type molding often is a manual operation.
wear are reduced. Basically, there are three This method is usually faster than compres-
variations of this technique, as described in the sion molding, as the cure time, particularly for
following paragraphs. thick sections, often is shorter because the pre-
heated material is introduced into the cavity at
Transfer Mold in Compression Press. With high speed through a restricted gate, imparting
this type, a single, hydraulic ram is used. The considerable mechanical shear to the flowing
plunger for the pot is clamped to the upper compound with resultant frictional heat. The
platen of the press . Pressure is developed in the sharp increase in temperature throughout the
pot by the action of the main hydraulic ram of material charge enables rapid curing of molded
the press . The area of the pot should exceed the parts with good dimensional control and uni-
area of the cavities by a minimum of 10% . form density. The mold cost for transfer mold-
272 SPI PLASTICS ENGINEERING HANDBOOK

ing usually is higher than for compression in this method. This forces the preheated ma-
molding, however, and the process is not well terial through runners into the cavities of the
suited to automatic operation. closed mold. A two-plate mold is used. Gen-
A three-plate mold is used with the ram or erally this type of molding is a semiautomatic
plunger in the top plate (Fig. 9-14) . Because operation with self-contained presses.
the material enters the cavity at a single point, Basic steps of this process are similar to those
orientation of any fibrous filler is produced in of the pot or transfer molding method. When
a direction parallel to the flow. The shrinkage the plunger is withdrawn and the mold opened,
of the molded part parallel to the line of flow the molded part may be removed from the cav-
and the shrinkage at right angles to the line of ity with the runners and cull still attached as a
flow thus may be different and rather difficult unit. The overall molding cycle in plunger
to predict, depending upon the geometry of the molding usually is shorter than for transfer
molded part and the position of the gate. molding because removal of the sprue, run-
When a transfer mold is opened, the residual ners, or cull does not require a separate oper-
disc of material left in the pot, known as the ation. In plunger molding, it is essential that
cull, and the sprue (or runner from the pot into radio frequency preheated preforms be used to
the cavities) are removed as a unit. To remove take maximum advantage of the fast cures ob-
the molded part from the bottom section of the tainable. Figure 9-15 illustrates this process.
mold, ejector pins generally are used on the The mold temperature and pressure required
parts as well as on the runners. to obtain a satisfactory molded piece must be
In pot-type transfer, the taper of the sprue is predetermined for each type of thermosetting
the reverse of that used in injection molding material used. A detailed plunger mold is
because the goal is to keep the sprue attached shown in Fig. 9-13 .
to the cull so that it will pull away from the
part. A detailed pot type is shown in Fig . 9-12. Screw-Transfer Molding. In this process,
the material is preheated by preplasticizing in
Plunger Molding. Sometimes called auxil- a screw and is dropped into the pot of an in-
iary ram transfer, plunger molding is similar to verted plunger mold mounted in a downward
transfer molding except that an auxiliary ram is clamping press with fixed bottom platen. The
used to exert pressure on the material in the pot preheated material is transferred into the mold

i
-<} -$ -
-0. ~!~ -CD-

.,
-<)"---1M I
"r- $-

Fig. 9-14. Molding cycle of a transfer mold. Material is placed in the transfer pot (left), then forced through an orifice
into the closed mold (center). When the mold opens (right) , the cull and sprue are removed an a unit , and the part is
lifted out of the cavity by ejector pins. (Courtesy Chemicals and Plastics Company. Inc. )
 COMPRESSION AND TRANSFER MOLDING 273

Fig. 9-15. Plunger molding. An auxiliary ram exerts pressure on the material in the pot (left) and forces it into the
mold (center). When the plunger mold is opened (right) , the cull and sprue remain with the molded piece. (Courtesy
Chemicals and Plastics Company , Inc. )

by the same method as shown in Fig . 9-15 . The is to prepare material as hot as possible without
screw transfer process and the sequence of op- precuring the resin. Variables such as the water
eration are shown in Figs. 9-16 and 9-16a. This temperature of the barrel jackets, screw rota-
molding technique lends itself particularly well tional speed, and back pressure applied to the
to fully automatic operation. The optimum screw as it prepares the material serve to con-
temperature of a phenolic mold charge is 240° trol the amount of heat input to the material.
±20°F, the same as that in RF preheating for In the screw-transfer process (Fig. 9-16a),
transfer and plunger molding. thermosetting material is gravity-fed from a
Screw-transfer presses are equipped with larger storage hopper through a hole in the bar-
screw units capable of preparing from 3-ounce rel to the reciprocating screw preplasticizer. As
to 5-pound shots. To provide adequate control the screw rotates, material travels forward
of preheating of the material in the screw units, along the flights and is thoroughly preheated by
certain requirements are necessary. The mechanical shearing action. The material flows
compression ratio (ratio of shallowest to deep- off the end of the screw and begins to accu-
est depth of flight) for a thermoset screw trans- mulate. This buildup of material pushes the
fer is much less than the ratio for screws avail- screw back along its axis (away from the trans-
able for thermoplastic materials. The length-to- fer pot) to a predetermined point, which can be
diameter screw ratio, in most cases, is consid- set by a limit switch. The amount of reverse
erably shorter. Because of the exothermic re- travel of the screw establishes the volume of
action of most thermoset resins, a means to the charge. While the shot is being preplasti-
carry away heat generated in the barrel also is cized, the transfer ram is in the raised position,
provided. Aluminum water jackets surround the blocking the opening into the transfer pot.
barrel, permitting the circulation of water. The After the shot is formed, the transfer ram re-
temperature of this water is regulated by sepa- turns to its lower position, leaving the opening
rate control units. Normally, one water control to the transfer pot completely clear. At this
unit is provided for each temperature zone of point, the screw moves forward, pushing the
the barrel. Some machines even are provided preheated material into the transfer pot. With
with plasticizing screws that are channeled to the press closed, the transfer ram advances, de-
permit the circulation of controlled-tempera- livering the preplasticized material to the run-
ture water. The object of the plasticizing units ners and cavities.
274 SPI PLASTICS ENGINEERING HANDBOOK

Clamping (am

Fig. 9-16. Screw-transfer process.

Transfer Molds

The vast majority of transfer molds used today

are of the auxiliary ram type, using a transfer
plunger actuated by a hydraulic ram that is part
of the press and operates independently of the
press clamping ram. For historical purposes,
and also because some of the older-type trans-
fer molds may still be in use, the following sec-
tions on loose-plate molds and integral molds
have been included.

Loose-Plate Molds. This classification may

be subdivided into manual and semiautomatic
types, depending on the method of mounting
and the operation.
One of the earliest and simplest hand-trans-
fer molds is illustrated in Fig. 9-17. This mold
is especially useful where the molded piece
contains a group of fragile inserts extending
completely through it. The mold consists of a
plunger, a loose plate with orifices around its
perimeter, and the cavity. The space in the cav-
ity above the loose plate serves as the pot or
transfer chamber.
E
In operation, the inserts are loaded into the
loose plate, which is then inserted into the cav-
ity so that the lower ends of the inserts enter Fig. 9-16a. Screw-transfer sequence. In A, the material
the proper holes. The compound is loaded into is preplasticized as it travels along the flights of the screw.
In B, material builds up to the end of the screw and forces
the mold above the loose plate and is trans- it to move backward a predetermined distance. In C, after
ferred by the plunger through the orifices into the shot is formed, the transfer ram lowers to open the
the closed mold. After-curing, the molded transfer pot. In D, the screw moves forward to push the
piece, loose plate, and cull are ejected by material into the transfer pot. In E, the transfer ram then
knockout pins, and disassembled at the bench. advances through a standard bottom-transfer molding
operation to inject the material into the mold. (Courtesy
Two plates may be used alternately to speed up Stokes Div., Pennwalt Corp. )
production by keeping the press continually in
operation.
 COMPRESSION AND TRANSFER MOLDING 275

Integral Molds. As the name indicates, these

molds are self-contained; each one has its own
pot and plunger. This arrangement frequently
increases the efficiency of the mold because the
transfer pot can be designed for best results with
a specific cavity. A simple type is illustrated in
Fig . 9-19.
Molds of this type can be designed for either
manual or semiautomatic operation . The trans-
fer chamber may be located above or below the
mold cavity, and the material may flow through
a sprue, runner, and gate to the cavity, or the
sprue may enter the cavity directly, as in the
illustration.

Auxiliary-Ram Molds. Molds of this type are

illustrated in Figs. 9-20 and 9-21. These are
integral molds, in which the transfer plunger is
operated by a separate double-acting cylinder
mounted on the press head. Figure 9-22 shows
a molded shot from the mold illustrated in Fig.
9-21.
As mentioned previously, this transfer cyl-
inder and plunger may be mounted on the bot-
tom press platen, within the main ram, or even
on the tie rods or side columns of the press.
Fig. 9-17. Loose-plate or hand-transfer mold. (I)
These various methods of mounting are usually
Plunger; (2) cavity; (3) loose plate; (4) inserts; (5) gate; described as top-ram, bottom-ram, or side-ram
(6) knockout pin . mounting, and the molds are designated ac-
cordingly .
In comparing the advantages and disadvan-
These molds are most useful when the cost tages of the various designs of auxiliary-ram
of the mold must be as low as possible, and methods, it is difficult to generalize because of
when the volume of production is small. limiting factors in each design and the method
Figure 9-18 shows a semiautomatic mold as- of operation. The statements that follow are
sembly of the loose- or floating-plate type. In therefore made in the realization that special
this case, the floating plate is carried more or conditions in individual plants may alter con-
less permanently in the press and has a central siderably the conclusions given.
opening that will accommodate stock-transfer Top-ram molds are most prevalent today de-
pots and plungers of various sizes , as required spite some awkwardness in loading the charge
by different molds. In this way the design of due to the restricted opening above the transfer
the mold itself is simplified. Presses equipped pot and between the upper bolsters. Aside from
with these floating plates have been called this inconvenience , top-ram molds normally
transfer presses, but are not to be confused with will permit a faster cycle, after loading, be-
auxiliary-ram transfer presses. Movement of cause the mold is already closed at the start of
these loose plates may be accomplished either the cycle. There are certain exceptions to this
by latches or bolts built into the mold or by statement, however, as will be noted later.
auxiliary pneumatic or hydraulic cylinders at- Another factor to be considered in any ap-
tached to the press. praisal of top-ram molds is the difficulty of
276 SPI PLASTICS ENGINEERING HANDBOOK

Fig. 9-18. Design of transfer mold for use in a transfer press. The press has a floating platen that will receive several
standard sizes of transfer chamber. (I) Top plate; (2) upper force plate; (3) floating platen; (4) force plate; (5) cavity
plate; (6) backing-up plate; (7) parallel; (8) pin plate; (9) knockout bar; (10) bottom plate; (II) upper force; (12) loading
chamber; (13) sprue plug; (14) molded article; (15) force; (16) cavity; (17) chase; (18) guide pin.

using top ejection mechanisms with this de-

sign, because of the space required for the
transfer cylinder and ram.
Bottom-ram molds are easier to load than the
top-ram type because they are open, and the
transfer well is readily accessible, at the begin-
ning of the cycle. However, the molding cycle
may be longer, because the mold must be
closed, after loading, before the transfer ram is
actuated .
When a bottom-ram mold is mounted in a
conventional upstroke compression press, some
of the stroke and opening must be sacrificed to
provide mounting space on the lower press
platen for the transfer cylinder. In some cases
this can be offset by the use of longer side col-
umns or strain rods.
In bottom-ram transfer and screw-transfer
Fig. 9-19. The "integral" or "accordion" type of
transfer mold . (I) Plunger; (2) loading chamber or transfer presses, the transfer cylinder and ram are con-
pot; (3) sprue; (4) cavity plate ; (5) cavity; (6) molded tained within the main ram. This saves opening
article; (7) force. or daylight in the press .
 COMPRESSION AND TRANSFER MOLDING 277

Fig. 9-20. Design of a pressure-type of transfer mold that makes use of the conventional press for clamping pressure
only. Transfer is effected by means of an auxiliary ram. (I) Plunger; (2) loading chamber; (3) guide pin; (4) force plate;
(5) cavity plate; (6) parallel; (7) pin plate; (8) knockout bar; (9) pin-plate screw; (10) bottom plate; (11) force; (12)
cavity.

Side-ram molds are less common, and are They can be preheated most rapidly and effec-
used primarily where the design of the molded tively in dielectric equipment.
article requires injection of material at the part- In entering the mold, the material flows in
ing line. Theoretically, this design permits use thin streams through small runners and gates.
of the full clamping area of the mold, but in This promotes heat transfer, and may also mo-
actual practice, unless the molding material is mentarily add some heat to the material through
extremely soft and fluid and the transfer pres- friction and mechanical work. Most phenolic
sure low, there is a distinct tendency for the materials also are homogenized thereby, and
mold to spring and flash as a result of localized, volatile matter, which might otherwise remain
unbalanced transfer pressure near the gate. in the piece and necessitate a longer cure to
Whatever method of mounting is used, it is avoid blistering, is reduced in passing through
now generally conceded that the auxiliary-ram these small channels and by escape through
method of transfer permits the highest produc- vents and clearance spaces around movable
tion with the lowest mold cost and minimum pins . All of these factors contribute to substan-
loss of material in sprues, runners, and culls. tially shorter molding cycles than are possible
Other advantages, common to this and other in compression molds, without preheating.
types of transfer molding, are discussed below.
Mold design is covered in more detail in Tool and Maintenance Costs. Deep loading
Chapter 10. wells are not necessary with transfer molds, and
mold sections can be thinner than in compres-
sion molds because they are not required to
Advantages of Transfer Molding withstand the higher stresses involved during
closing of the latter. This difference obviously
Molding Cycles. Loading time usually is permits an initial savings in tool costs.
shorter in transfer molding than in compression This is less wear on the mold in transfer
molding, as fewer and larger preforms are used. molding and much less tendency toward break-
278 SPI PLASTICS ENGINEERING HANDBOOK

Fig. 9-21. Four-cavity auxiliary-ram transfer mold. (Courtesy Eaton Corp. )

Fig. 9-22. Shot from plunger transfer mold illustrated in Fig. 9-21. (Courtesy Eaton Corp. )

age of pins. In transfer molds, core pins can that ordinarily can be used is 4: I using di-
readily be piloted in the opposite half of the electrically preheated preforms and about 2.5: 1
mold. When so designed, core pins having a using cold powder. Transfer molds retain their
length-to-diameter ratio of 8: I can safely be original accuracy and finish considerably longer
used; in compression molds the largest ratio than d9 compression molds.
 COMPRESSION AND TRANSFER MOLDING 279

Molding Tolerances. Because the articles are In a transfer-molded article, assuming a prop-
produced in closed molds which are subjected erly designed mold with adequate clamping
to less mechanical wear and erosion by the pressure, the flash is quite thin or altogether ab-
molding material than are compression molds, sent.
closer tolerances on all molded dimensions Gates, except in certain cases with fabric-
should be possible in transfer molding. This is filled phenolics, usually can be made suffi-
particularly true of dimensions perpendicular to ciently thin and can be so located that their re-
parting lines, because ofthe very small amount moval is easy and inexpensive. It may be pos-
of flash in properly designed and operated sible to gate into a hole in the molded piece and
molds of this type. to remove the gate by drilling.
Also, it should be possible to hold closer tol-
erances on diameters of holes and dimensions
Limitations of the Process
between holes because forces in the mold that
tend to distort or displace pins or inserts are As might be expected, there are certain inher-
much less in transfer molding. ent limitations in transfer molding, are dis-
This is the theoretical ideal that could be at- cussed below.
tained if no other factors than those mentioned
above were at work in the process. Actually, Mold Costs. The statements concerning lower
warpage and dimensional variations have oc- mold costs apply particularly to auxiliary-ram
curred in numerous instances in plunger- transfer molds. Pot-type transfer molds may, in
molded articles, and it is not always possible some cases, be more expensive than equivalent
in these cases to achieve the close dimensional compression molds, without offsetting advan-
tolerances hoped for. tages.
Careful study has indicated that these diffi-
culties are caused, in most cases, by abnormal Loss of Material. The material left in the pot
shrinkage and internal strains set up in the or well (the cull), and also in the sprue and run-
molded articles by improper gating and exces- ners, is completely polymerized and must be
sive transfer pressure. In some instances, the discarded. This loss of material is unavoidable,
article, although complicated in outline and and for small articles it can represent a sizable
section, may not lend itself to transfer molding percentage of the weight of the pieces molded.
because of peculiarities of its design. In the auxiliary-ram molds, the cull is reduced
Those who have studied the auxiliary-ram to a minimum, and the main sprue is elimi-
transfer process most thoroughly are convinced nated.
that in most instances close tolerances can be Some years ago, transfer molding was not
held, and optimum dimensional stability real- well suited to the production of small molded
ized if, and only if, the preheating, the plastic- items because of this loss of material. How-
ity of the material, and the transfer pressure are ever, to meet the increasing trend toward min-
accurately controlled, and if the runners and iaturization and increased demands for close
gates are so located, and of such size and shape, tolerances and thin-wall sections in molded
as to permit rapid, free flow of the material into electronics parts, methods were developed to
the closed mold. use small, fully automatic transfer molding
presses for the economical production of such
Finishing Costs. Transfer molding reduces small items. Although loss of material in cull
the costs of finishing all thermosetting mate- and runners is still a factor in molding costs for
rials, and especially those having cotton flock these small parts, the savings elsewhere, in-
and chopped fabric as filler. In an article cluding mold costs and finishing costs, usually
molded with the latter materials in a compres- offset the loss of material.
sion mold, the flash frequently is heavy, tough, On the other hand, where large-volume pro-
and expensive to remove; this condition be- duction (in excess of 500,000 pieces) is re-
comes even worse as the mold becomes worn. quired, and where cross sections are simple and
280 SPI PLASTICS ENGINEERING HANDBOOK

uniform, as in buttons and bottle caps, produc- Urea-formaldehyde materials have been
tion by compression molding-in multicavity transfer-molded quite successfully in some
semiautomatic or automatic molds, with elec- cases, principally for small articles, but be-
tronic preheating-may be cheaper. cause of their reactivity and critical behavior in
dielectric preheating, the process has not been
Effect on Mechanical Strength. With wood- found as generally satisfactory with them as
flour-filled phenolic materials, no significant with the phenolics and melamines.
loss of mechanical strength attributable to the The alkyd or polyester molding materials
transfer-molding process has been observed in have been tried in transfer molds. In certain in-
laboratory tests on standard ASTM specimens. stances, they have proved suitable for smaller
This conclusion has correlated reasonably well articles, but their extremely fast rate of reaction
with general production molding experience. has prevented their use in larger molds and in
Some instances of cracking around inserts articles where considerable plastic flow is re-
and at weld lines have been noted in commer- quired.
cially molded articles, especially with mineral-
filled phenolics and melamine materials, which Phenol-Formaldehyde. Phenolic materials of
have inherently lower mechanical strength. all of the standard types, containing any of the
Changing the design and location of gates, al- usual fillers, can be successfully molded by
tering the cycle of preheating, or reducing the transfer. The principal types used are listed be-
volatiles content of the molding material, when low:
tried separately or in combination, have over-
come these difficulties in many cases; in some Type Filler
severe cases, however, no practicable remedy
could be found within the framework of the General-purpose Wood flour
transfer molding process, and it was necessary Heat-resistant Asbestos
Medium-impact Cotton flock or fabric
to mold the articles by compression in order to
High-impact Cotton fabric
overcome the trouble. Highest-impact Chopped cotton cord
With transfer molding of the improved-im- Low-electrical-loss Mica
pact materials containing fibrous fillers, a def-
inite and sometimes marked decrease in For satisfactory use in transfer molding, a
strength from values obtained in compression phenolic material must be extremely fluid at
molding has been noted by a number of inves- molding temperature in order to flow readily
tigators. This effect on strength can be mini- through runners and gates and form dense ho-
mized by the use of lower transfer pressures mogeneous molded articles. For most econom-
and larger gates. ical production, this flow should be accom-
plished in the shortest possible time; that is, the
Comparison between Compression and material should have a rapid rate of flow. Phe-
Transfer Molding nolic materials possess these properties and,
with the aid of dielectric preheating, give ex-
A comparison of the two molding techniques is cellent results in all types of transfer molds.
provided in Table 9-2, as many parts may be
molded by either of these methods. Molding Melamine-Formaldehyde. Mineral-filled,
technique selection frequently depends upon the cellulose-filled, and fabric-filled melamine ma-
molder's own economics and capabilities. terials have been employed in transfer molding
with good results. Certain melamine-urea for-
Materials Used mulations and melamine-phenolic formulations
also have shown good characteristics in trans-
Phenol-formaldehyde and melamine-formalde- fer molding.
hyde molding compounds are the materials Melamine materials may require some mod-
most widely used in transfer molding, gener- ification of basic properties in order to produce
ally giving excellent results. the best flow in transfer. These compounds as
 COMPRESSION AND TRANSFER MOLDING 281

Table 9-2. Compression vs. transfer molding.

Characteristic Compression Transfer
Loading the mold 1. Powder or preforms. 1. Mold closed at time of loading
2. Mold open at time of loading. (assuming top transfer, bottom
3. Material positioned for optimum clamp).
flow. 2. RF heated preforms placed in
transfer pot.

Material temperature before mold- 1. Cold powder or preforms. RF heated preforms to 220-280°F.
ing 2. RF heated preforms to 220-
280°F.

Molding temperature 1. One step closures-350-450°F. 290-360°F.

2. Others-290-390°F.

Pressures 1. 2000-10,000 psi (3000 optimum 1. Plunger head-2000-6000 psi

on part). on material.
2. Add 700 psi for each inch of 2. Clamping ram-minimum ton-
part depth. nage should be 75% of load ap-
plied by plunger ram on mold.

Breathing the mold Frequently used to eliminate gas 1. Neither practical nor necessary.
and reduce cure time. 2. Accomplished by proper vent-
ing.

Cure time (time pressure is being 30-300 sec-will vary with mass of 45-90 sec-will vary with part ge-
applied on mold) material, thickness of part, and pre- ometry.
heating.

Size of pieces moldable Limited only by press capacity. About 1 lb maximum.

Use of inserts Limited-inserts apt to be lifted out Unlimited-complicated. Inserts

of position or deformed by closing. readily accommodated.

Tolerances on finished products 1. Fair to good-depends on mold Good-close tolerances easier to

construction and direction of lo- hold.
cal flow of material during final
closing.
2. Flash-poorest. Positive-best.
Semipositive-intermediate.

Shrinkage Least. 1. Greater than compression.

2. Shrinkage across line of flow is
less than with line of flow.

a class show greater after-shrinkage than do flow. As with other fiber-filled types, precau-
phenolics. This tendency exists more or less in- tions must be taken to use gates of adequate
dependently of the method of molding; it can cross section to maintain proper strength. After-
be considerably reduced by proper control of baking at temperatures up to 200°C usually is
the resin and its compounding, and by suitable practiced to obtain optimum strength and heat
preheating before molding. resistance.
Soft flowing epoxy and silicone molding
Silicones. Glass-filled silicone materials are compounds, molding at pressures of several
molded by transfer methods for special high- hundred psi, are extensively used in transfer
impact heat-resistant applications. Dielectric molding to "encapsulate" or mold plastic
preheating is recommended to improve the around electrical or electronic components,
282 SPI PLASTICS ENGINEERING HANDBOOK

Fig. 9-23. Typical mold and loading frame, after molding, for transfer encapsulation of electronic integrated circuits,
with a soft-flowing epoxy or silicone molding compound. (Courtesy Hull Corp. )

such as diodes, transistors, integrated circuits, to mount the mold cavities, forces, and runners
resistors, capacitors, solenoid coils, and mod- as separate hardened-steel inserts in the mold
ules containing several such components. In chases or retainer plates. This permits removal
such applications, the materials provide elec- of individual mold cavities and runner blocks
trical insulation, moisture protection, and me- for repair or replacement when wear or break-
chanical protection (see Fig. 9-23). age occurs. Where not precluded by other fea-
tures of design, such as location of electric
heating cartridges and ejector pins, a circular
Theoretical and Design Considerations layout of mold cavities with short radial run-
ners from the central well is preferred. How-
There are many different opinions within the ever, there are numerous examples of success-
industry about the design of transfer molds, as ful transfer molds having various ladder and
well as molding pressures and molding tech- multiple-"T" arrangements.
niques. Because of the many factors involved, The center pad beneath the transfer pot
no hard-and-fast rules can be given to serve as should be hardened and well supported to pre-
infallible guides in the design and operation of vent deflection and consequent flashing Of the
these molds. The principal factors are listed be- mold. Similarly, all mating mold surfaces
low, and recommendations based on experi- should be ground smooth and perfectly flat to
ence and successful current practice are given. provide uniform contact. It is not imperative
(See also Chapter 10.) that cavities and runners be chrome-plated, but
this is usually advisable to improve release from
Mold Design. It is considered good practice the mold and to reduce wear, particularly in the
in multiple-cavity plunger-type transfer molds runners.
 COMPRESSION AND TRANSFER MOLDING 283

Runners, Gates, and Vents. The design of Because of the coarseness of the fillers used
runners and the size and location of gates can in high-impact materials, larger gates usually
be controversial subjects. The recommenda- are necessary, both to lessen the transfer pres-
tions given below are in accord with current sure required and to prevent impairment of the
practice, but are not intended to be inflexible mechanical strength of the molded articles. In
rules. these cases, a width of 0.500 inch and a depth
Main runners are usually ~ to ~ inch wide of 0.125 inch may be needed. A gate that is too
k
and inch deep, and semicircular in section; small may become partially blocked with fiber
branch runners, where used, should be about k fillers such that only the low viscosity resin
inch wide and f2 inch deep. These runners are flows into the cavity, without adequate filler,
located in the half of the mold containing the yielding a part of unacceptable strength.
ejector pins; this is usually the plate opposite These are general recommendations; it may
the transfer pot. The runners should be kept to well be necessary, in individual cases, to en-
minimum length and should extend into the pad large gates beyond these dimensions, depend-
at the bottom of the pressure well at least! inch. ing on circumstances. It is always easier, in any
The location, size, and shape of gates are case, to remove metal from a mold than to add
quite important to proper operation of the mold. it.
There are many conflicting opinions concern- Vents are important to permit the escape of
ing location, and striking individual exceptions air, moisture, and other volatiles as the mate-
may be found on particular jobs, but it is con- rials fill the mold cavity. It frequently is found
sidered good practice to place the gate at the that without proper vents the mold cavities will
thickest section of the molded article, and, not fill properly even under high transfer pres-
whenever possible, at a readily accessible point sures. Vents should be located on the same half
on the article, so that it can be removed by sim- of the mold as the runners, and opposite the
ple sanding or filing. gate. They usually are 0.003 to 0.005 inch
The size of the gate will vary with the type deep, and about l inch wide, and are extended
of material molded, the size of the piece, and to the outer surface of the mold block or land
the molding pressure available. For small area. With epoxies and silicones, vent depths
pieces, and where general-purpose wood-flour- are only 0.001 to 0.002 inch.
filled phenolics are used, it is recommended
that the gate be 0.80 to 0.100 inch wide and Vacuum Venting. To overcome the trapping
0.015 to 0.020 inch deep. With mineral-filled of air or gas in a cavity, in locations that are
materials, a gate 0.125 inch wide and 0.030 difficult to vent effectively, molds may be de-
inch deep usually is necessary. signed such that all cavity vents feed into a
The shape of gates for transfer molds has re- space that is sealed from the outside of the mold
ceived considerable attention. Depending on (when closed) by an O-ring seal, and is con-
the size and shape of the molded part, gates of nected to a vacuum reservoir through a vacuum
circular or rectangular cross section may be line containing a solenoid-operated valve. In
used. The circular gate generally permits most operation, as soon as the mold is closed, and
rapid filling with smallest gate area, but it may the transfer plunger enters the pot, the afore-
leave an unsightly scar on the finished part. mentioned solenoid valve is automatically
Often fan gating or edge gating is used, with opened, causing the cavities to vent rapidly into
gates from 0.010 to 0.020 inch thick, and as the vacuum reservoir before the molding com-
wide as several inches (perhaps as wide as the pound has entered or filled the cavities. Two
part). Such gates, ifshaped such that the runner benefits result: First, the material, finding it
approaching the gate is always of thicker and unnecessary to "push" the air from the cavity
larger cross section than the gate itself, will through the vents, enters with a minimum of
permit clean break-off of the part from the run- back pressure and thus fills the cavity more rap-
ner with minimum scar and often no further fin- idly, leading to faster cures. Second, not only
ishing costs. is there essentially no entrapped air, and there-
284 SPI PLASTICS ENGINEERING HANDBOOK

Vacuum
chamber TTIIn::Q=!=~T ransfer
Vacuum plunger
Vacuum
pump valve_ w.r..........."'""-J~~- 0 - r i ngsea I
r'-'--'---";':':":';=--..J.-~-Ca vi tie s

Encapsulating
machine

Fig. 9-24. Schematic diagram showing principle of vacuum venting with transfer molding . The principle also is used
with automatic transfer and screw injection molding where the cavity configuration precludes adequate parting line venting.
(Courtesy Hull Corp. )

fore no voids in the part, but such minute quan-

tities of air as may be present are readily ab-
sorbed "into solution" in the molding
compound because of the molding pressure.
Vacuum venting has been used successfully
in both semiautomatic and fully automatic
transfer molding, as well as in automatic in-
line screw injection molding. (See Figs. 9-24
and 9-25 .)

Selection of Material. The problem here is

three-fold-to choose the type of material that
will yield the desired physical properties in the
molded article (e.g., impact strength, heat re-
sistance, or low electrical loss); to choose from
among a number of formulations of this type
the one having the proper preheating and mold-
ing characteristics for the mold in question;
and, finally, to choose the proper plasticity,
which will provide the fastest transfer and cure.
The last cannot be decided in advance; it must
be determined by experiment.
Choice of the proper plasticity is very im-
portant. A material that is unduly stiff will be
Fig. 9-25. Multicavity transfer mold arranged for vacuum
extremely critical in behavior during preheat-
venting . Note rectangular O-ring seal surrounding the six ing, and may not fill the mold; a material that
bottom chases . (Courtesy Hull Corp. ) is too soft may flash the mold or require exces-
 COMPRESSION AND TRANSFER MOLDING 285

sive preheating to attain a satisfactorily rapid the design of an article and of the mold and in
cure. the molding conditions, it is practically impos-
A maximum transfer time of 10 to 15 sec- sible to calculate the minimum transfer pres-
onds at a mold temperature of 320 to 350°F, sure required to mold a given article. Only em-
with a preform temperature of 220 to 260°F, pirical assumptions can be made, based on
usually is found satisfactory. Individual con- limited experimental data and on previous pro-
ditions may necessitate some departure from duction-molding experience.
these values, but these represent the average of For soft-plasticity, general-purpose phenolic
general experience. materials, electronically preheated, minimum
transfer pressures of 8000 psi for plunger-type
Molding Pressure. It would be extremely dif- and of 12,000 psi for pot-type transfer molding
ficult, if not impossible, to measure accurately, generally are recommended. This assumes a to-
or to calculate theoretically, the magnitude and tal runner area of about 0.05 sq. in., and is valid
distribution of pressure within thermosetting primarily for quantities of material of the order
material flowing in a transfer mold. If all of the of 100 grams. For quantities of material greater
factors involved were in perfect dynamic bal- than 100 grams, enlarge the runner and gate
ance, there would be no unbalanced fluid pres- areas by 50 to 100 %.
sure in the mold cavity at the moment of com- For fabric-filled phenolic materials also, a
plete filling. 50% increase in transfer pressure usually will
Initially, with either pot or plunger molds, be required to keep transfer time to an econom-
fluid pressure in the hydraulic line to the press ical minimum. Here, too, larger gates, as rec-
is converted to mechanical pressure on the ommended previously, should be used.
molding material as the latter is compressed and
forced into the closed mold. As the mold fills, Design Calculations. The various factors in-
and polymerization of the material continues, cluded in the design of plunger transfer molds,
this pressure builds up to a maximum. Ideally, insofar as pressure is concerned, can be defined
the material continues to be fluid until the cav- and illustrated as follows:
ity is completely filled and "packed." At that
point, and not before, the cross~linking reac- 1. Line pressure: The pressure in psi in the
tion should proceed to harden the part suffi- hydraulic line to the press, supplied either
ciently for ejection. by a self-contained pump or from a cen-
It is recognized that at the instant of cavity tral pump and accumulator system.
fill and packing, there is a hydrostatic pressure 2. Clamping-ram force: The total force de-
exerted against top and bottom mold halves, livered by the main ram, determined by
tending to open the mold. Calculation of the multiplying the ram area by the line pres-
actual clamping force required to counterbal- sure.
ance this pressure is difficult because pressure 3. Transfer-ram force: The total force ap-
throughout the cavity and runner system is not plied by the transfer ram, expressed in
uniform; but if the force calculated by multi- pounds, determined by multiplying the
plying the projected area of cavities and run- hydraulic ram area by the line pressure.
ners and cull times the calculated hydraulic 4. Plunger pressure: The pressure exerted
pressure at the plunger head (where the plunger on the material in the transfer chamber by
meets the plastic) is greater than the clamping the plunger. It is equal to the transfer ram
force, the mold will open and flash. Good mold force divided by the area of the plunger.
design requires a minimum of a 10 to 15% 5. Mold-clamping pressure: The effective
margin of extra clamping force over the pro- pressure that holds the mold closed
jected area "hydrostatic force" to preclude against the pressure exerted by the ma-
mold opening before cure. terial within the mold cavities and run-
Because of the many variables involved in ners. It is expressed in psi and is deter-
286 SPI PLASTICS ENGINEERING HANDBOOK

mined by dividing the clamping-ram force Am = 4x

by the total projected area of cavities, A = 3.1416 X 142
4 154 sq. in.
lands, runners, and cull in square inches. r

These factors can be shown symbolically as 3.1416 X 62

follows: Ai = 4 = 28.3 sq. in.

L\ = line pressure, psi, clamp 3.1416 X 32

~ = line pressure, psi, transfer Ap = 4 = 7.1 sq. in.
Am = projected area of each mold cavity,
land, and runner, sq. in.
CRF = Ar X L = 154 X 2,000
Ar = area of clamping ram, sq. in.
308,0001b
Ai = area of transfer hydraulic piston, sq.
in.
TRF = Ai
X L = 28.3 X 2,000
56,6001b
Ap = area of plunger, sq. in. (also equal
to cull area) PP = Ai X L = 56,600
CRF = clamping-ram force (Ar x L\), lb Ap 7.1
TRF = transfer-ram force (Ai X ~), lb = 8085 psi
PP = plunger pressure, psi (Ai x ~) Ar X L 308,000 .
Ap MCP=
Am + Ap = 4x + 7.1 pSI
. (A xL)
MCP = mold-clampmg pressure r 1 ,
Am + Ap Since MCP = 1.15 PP
psi
308,000
By definition, to ensure safe operation and = 1.15 X 8085 = 9298 psi
avoid flashing, mold-clamping pressure = 4x + 7.1
plunger pressure + 15%, or:
308,000
4x + 7.1 = 9298 = 33.1
MCP = 1.15 PP

Practical application of this simple equation 4x = 26

is demonstrated in the following example. x = 6.5, or 6 cavities
Example. Determine how many cavities can
be placed in a mold that is to operate under the Ar X L 308,000 .
MCP=
following conditions: Am + Ap = 4x + 7.1 pSI

Projected area of molded article including In designing pot-type transfer molds, where
land area = 3 sq. in. the only source of external pressure is the main
Estimated runner area per cavity = 1 sq. in. ram, the pot area is equated to the total mold
Total area per cavity = 4 sq. in. area, and, as mentioned previously, the latter
Diameter of main ram = 14 in. is increased by 15 % to prevent flashing.
Diameter oftransfer hydraulic piston = 6 in.
Plunger diameter = 3 in. Let:
Line pressure = 2000 psi, both clamp and
transfer L = line pressure, psi
Ar = area of main ram, sq. in.
Let: Ap = projected area of pot or material
chamber, sq. in.
x = the number of cavities Am = projected area of mold cavities,
L = 2000 psi (L1 and ~) lands and runners, sq. in.
 COMPRESSION AND TRANSFER MOLDING 287

CF = clamping force (Ar xL), lb ness and density of preforms vary, then the
MCP = mold-clamping pressure temperature will vary considerably throughout
the preforms, and their behavior during transfer
and cure will be erratic. Once established, op-
timum preheating conditions should be main-
tained as nearly constant as possible for a given
Then for equilibrium, with the factor of batch of material. To facilitate uniform heating
safety: of cylindrical preforms, preheaters with auto-
matic roller electrodes cause the preform to ro-
(1) Am = 1.15 Ap tate under the top electrode during the actual
heating.
(2) A = Ar X L Numerous other factors affect transfer mold-
m MCP
ing, but they are already familiar to molders
Ar X L employing this method and need not be de-
(3) MCP = 1.15 Ap
scribed in detail. It has been the purpose of this
section, instead, to point out some of the im-
Other Considerations. It has been assumed portant features of this method, and the advan-
in the foregoing discussion of transfer-molding tages in increased production and lowered pro-
pressure that flashing will be prevented if suf- duction costs that may be achieved with it, if
ficient clamping pressure or area is provided. certain fundamental considerations are known
This is generally true if the mold is properly and observed.
supported, particularly under the transfer Although automatic transfer molding was
chamber. However, if insufficient bolstering is practiced extensively in the 1960s and 1970s,
used at this point, or if the mold is not properly automatic thermoset injection molding gener-
aligned or hardened, deflection can occur and ally has replaced it as the preferred process.
permit flashing in spite of the excess clamping (See Chapter 8.)
pressure provided in the design.
Transfer pressure should be sufficient to fill
the mold, under ordinary circumstances, in 10 Liquid Resin Molding
to 15 seconds. Excessive transfer pressure
should be avoided-it may cause flashing, it Liquid resin molding (LRM) is a combination
will probably cause undue wear of gates and of liquid resin mixing and dispensing and trans-
runners, and it may decrease normal molding- fer molding. The process equipment includes a
shrinkage so much that molded articles will be machine to proportion, mix, and dispense a
outside normal tolerances. resin and catalyst directly into a transfer mold,
The rate at which a phenolic material will be generally through a parting line sprue feeding
preheated in a dielectric preheater depends, into the runner system. Another version, suit-
among other factors, on the high-frequency able for long pot-life liquid resin systems, dis-
output of the machine and on the electrical-loss penses the resin mix from a storage chamber,
characteristics ofthe material involved. Wood- with the catalyst already added. (See Fig.
flour-filled compounds having a higher electri- 9-26.)
cal-loss factor, will preheat more rapidly than Because the pressures of injection are ap-
mica-filled materials. Modem dielectric pre- proximately 25 to 50 psi, very fragile inserts
heaters of 2.5 kW output and with frequency can be molded, and mold wear is at a mini-
of 100 MHz are designed to heat approximately mum. Some formulations for LRM also may be
1 pound of wood-flour-filled material from molded at temperatures as low as 200°F, which
room temperature to 300°F in 30 seconds. permit encapsulation of some heat-sensitive
Where a number of preforms are being pre- electronic components that do not lend them-
heated at one time, the uniformity of preheat- selves to encapsulation at conventional transfer
ing of the material is quite important. If hard- molding temperatures of 300°F or higher.
288 SPI PLASTICS ENGINEERING HANDBOOK

Fig. 9-26. Complete installation for liquid resin molding process. Apparatus at left proportions, mixes, and dispenses
liquid resin and liquid curing agent, which is then injected into closed molds at parting line, at pressures as low as 25
psi. (Courtesy Hull Corp. )

Liquid resin systems for LRM may be filled composites, the fiber mat or fabric layers are
or unfilled, They generally have a pot life of at placed in the open mold, following which the
least two hours at room temperature, but a mold is closed. Then the liquid unfilled low-
"snap cure" of often less than one minute at viscosity catalyzed resin (often epoxy or
mold temperature. Unlike liquid coating resins, polyester) is transferred into the cavity through
such resin systems must include a mold release one or more gates. The resin saturates the fab-
agent to enable easy removal of parts from cav- ric "insert" and cures under continued heat and
ities. pressure, producing a highly engineered com-
This process of transferring unfilled liquid posite component offering maximum strength
resins into heated mold cavities also is being and rigidity with minimum weight. The rein-
used increasingly in molding highly sophisti- forcing fabric used in such parts is sometimes
cated aerospace parts reinforced with oriented glass, but often graphite or boron fibers or Kev-
reinforcing woven fabric. In molding these lar synthetic fibers.