St.

Joseph’s College of Engineering Manufacturing Processes 2023-2024

UNIT 5 – MANUFACTURE OF PLASTIC COMPONENTS

Types and characteristics of plastics – Moulding of thermoplastics – working principles and

typical applications – injection moulding – Plunger and screw machines – Compression
moulding, Transfer Moulding – Typical industrial applications – introduction to blow moulding
–Rotational moulding – Film blowing – Extrusion – Thermoforming – Bonding of
Thermoplastics.

5.1 Introduction
Plastic is material consisting of any of wide range of synthetic or semi-synthetic organic
compounds. It can be easily elongated and molded into solid objects. They are derived from
the petrochemicals.The polymers are classified as:
1. Natural organic polymers,
2. Synthetic organic polymers.

The natural organic polymers were made of materials from animal and vegetable
products; cellulose is the most common example.

Figure 5.1. Outline of the basic process for making various synthetic polymers

5.2 Polymerization:
Monomers can be linked into polymers in repeating units to make longer and larger
molecules by a chemical process called a polymerization reaction. Although there are several
variations, two polymerization processes are important: addition and condensation
polymerization.
5.2.1. Addition polymerization
In addition polymerization also called chain-growth or chain-reaction polymerization,
bonding takes place without reaction by-products. It is called “chain reaction” because of the
high rate at which long molecules form simultaneously, usually within a few seconds.

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Addition polymerization: (1) initiation, (2) rapid addition of monomers, (3) resulting long
chain polymer molecule with n mers at termination of reaction.

5.2.2. Condensation polymerization

Condensation polymers are any kind of polymers formed through a condensation
reaction—where molecules join together—losing small molecules as byproducts such as
water or methanol. The main alternative form of polymerization gives addition polymers,
which derive from the conversion of alkenes to long-chain alkanes.

Model of step polymerization showing the two types of reactions occurring: (a) n-mer
attaching a single monomer to form a (n + 1) -mer; and (b) n1-mer combining with n2-mer to
form a (n1 + n2) -mer. Sequence is shown by (1) and (2).

5.2.3. Additives
The properties of a polymer can often be beneficially changed by combining them
with additives. Additives can be classified by
a. Filler:
Fillers will increase the stiffness and hardness of a plastic. They will also usually
reduce the cost of the compound as they are generally cheaper than the base polymer. Inert
fillers that are most commonly used include calcium carbonate (chalk), talc and barium
sulphate.
b. Plasticizers:
Plasticizers for plastics are additives, most commonly phthalate esters in PVC
applications. Almost 90% of plasticizers are used in PVC, giving this material improved
flexibility and durability.. The plasticizer works by reducing the glass transition temperature
to below room temperature. Whereas the polymer is hard and brittle below Tg, it is soft and
tough above it. Addition of a plasticizer to polyvinylchloride (PVC) is a good example. The
majority is used in films and cables.

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c. Colorants:
Colorants for polymers are of two types: pigments and dies. Pigments are finely powdered
materials that are insoluble. It is uniformly distributed in polymer, usually less than1%.
Dies are chemicals, usually supplied in liquid form, that are generally soluble in the
polymer. They are normally used to color transparent plastics such as styrene and acrylics.

d. Lubricants:
Lubricants are added to the polymer to reduce friction and promote flow at the mold
interface. Lubricants are also helpful in releasing the part from the mold in injection molding.
Mold-release agents, sprayed onto the mold surface, are often used for the same purpose.
e. Flame retardants
Nearly all polymers burn if the required heat and oxygen are supplied. Some polymers
are more combustible than others. Flame retardants are chemicals added to polymers to
reduce flammability
f. Cross-linking agent
It is an additive that cause cross-linking to occur in thermosetting polymers and
elastomers. The term cross-linking agent refers to a variety of ingredients that cause a cross-
linking reaction. Examples are sulfur in vulcanization of natural rubber.
g. Ultraviolet light absorbers, and antioxidants:
Many polymers are susceptible to degradation by ultraviolet light and oxidation. The
degradation manifests itself as the breaking of links in the long chain molecules.
Polyethylene, for example, is vulnerable to both types of degradation, which lead to a loss of
mechanical strength.

5.3. Types of Plastics

The plastics can be classified as: 1. Thermoplastics Plastics. 2. Thermosetting Plastics
Difference between Thermoplastics and Thermosetting plastics:

S.No Thermoplastics Thermosetting plastics

They can be repeatedly softened by heat They can be hardened and set, they do not
1.
and hardened by cooling. soften with the application of heat.
They are formed by addition They are formed by condensation
2.
polymerization polymerization
3. They can be remolded They can’t be remolded

4. Have low molecular weight Have high molecular weight

The structure is made of linear chain
5. The structure is made of cross chain molecules
molecules
Application: Automobile parts, Cameras, Application: Photographic films, Electric
6.
Electrical plugs, Telephone parts. insulations, tapes and hoses.

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5.3.1. Important commercial Thermoplastics

Acrylonitrile–Butadiene–Styrene:
 Acrylonitrile butadiene styrene (ABS) is a terpolymer synthesized from styrene and
acrylonitrile in the presence of polybutadiene.
 ABS is a light-weight material that exhibits high impact resistance and mechanical
toughness.
 It poses few risks to human health under normal handling.
 It is used in many consumer products, such as toys, appliances, and telephones.
Nylon:
 It is belongs to a class of polymers called polyamides.
 It has served as a substitute mainly for hemp, cotton and silk, in products such as
parachutes, cords, sails, flak vests and clothing.
 Nylon fibers are useful in making fabrics, rope, carpets and musical strings, whereas
in bulk form, nylon is used for mechanical parts including machine screws, gears and
power tool casings.
 In addition, it is used in the manufacture of heat-resistant composite materials.
Polyvinylchloride:
 (PVC) is a tough, lightweight material that is resistant to acids and bases.
 Much of it is used by the construction industry, such as for vinyl siding, drainpipes,
gutters and roofing sheets.
 It is also converted to flexible forms with the addition of plasticizers, thereby making
it useful for items such as hoses, tubing, electrical insulation, coats, jackets and
upholstery.
5.3.2. Important commercial thermosetting plastics
Amino Resins:
 Amino plastics, characterized by the amino group (NH 2), consist of two thermosetting
polymers, urea-formaldehyde and melamine-formaldehyde, which are produced by
the reaction of formaldehyde (CH2O) with either urea (CO(NH2)2) or melamine
(C3H6N6), respectively.
 Urea–formaldehyde is competitive with the phenols in certain applications,
particularly as a plywood and particle-board adhesive.
 The resins are also used as a molding compound.
 It is slightly more expensive than the phenol material. Melamine–formaldehyde
plastic is water resistant and is used for dishware and as a coating in laminated table
and counter tops (Formica, trade name of Cyanamid Co.).
 When used as molding materials, amino plastics usually contain significant
proportions of fillers, such as cellulose.
Epoxies:
 Epoxy resins are based on a chemical group called the epoxides. The simplest
formulation of epoxide is ethylene oxide (C2H3O).
 Epichlorohydrin (C3H5OCl) is a much more widely used epoxide for producing epoxy
resins. Uncured, epoxides have a low degree of polymerization.
 To increase molecular weight and to cross-link the epoxide, a curing agent must be
used. Possible curing agents include polyamines and acid anhydrides.

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 Cured epoxies are noted for strength, adhesion, and heat and chemical resistance.
 Applications include surface coatings, industrial flooring, glass fiber-reinforced
composites, and adhesives.
 Insulating properties of epoxy thermosets make them useful in various electronic
applications, such as encapsulation of integrated circuits and lamination of printed
circuit boards.
Silicones:
 Silicones are inorganic and semi-inorganic polymers, distinguished by the presence of
the repeating siloxane link (–Si–O–) in their molecular structure.
 A typical formulation combines the methyl radical (CH 3) with (SiO) in various
proportions to obtain the repeating unit –((CH 3)m–SiO)–, where m establishes the
proportionality.
 By variations in composition and processing, polysiloxanes can be produced in three
forms: (1) fluids, (2) elastomers, and (3) thermosetting resins.

5.3.3. Properties of Plastics

The properties of plastics are given as under.
 Plastics are light in weight and at the same time they possess good toughness strength
and rigidity.
 They are less brittle than glass, yet they can be made equally transparent and smooth.
 Their high dielectric strength makes them suitable for electric insulation.
 They resist corrosion and the action of chemicals.
 Low moisture absorption, Easily molded to desired shapes, bad conductance of heat.
5.4 Characteristics of Plastic forming and shaping process

Process Characteristics
Extrusion Continuous, uniformly solid or hollow, and complex cross
sections; high production rates; relatively low tooling costs; wide
tolerances
Injection molding
Complex shapes of various sizes; thin walls; very high production
rates; costly tooling; good dimensional accuracy
Structural foam
molding Large parts with high stiffness-to-weight ratio; less expensive
tooling than in injection molding; low production rates
Blow molding
Hollow, thin-walled parts and bottles of various sizes; high
production rates; relatively low tooling costs
Rotational molding
Large, hollow items of relatively simple shape; relatively low
tooling costs; relatively low production rates
Thermoforming
Shallow or relatively deep cavities; low tooling costs; medium

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production rates
Compression molding
Parts similar to impression-die forging; expensive tooling;
medium production rates
Transfer molding
More complex parts than compression molding; higher production
Casting rates; high tooling costs; some scrap loss
Simple or intricate shapes made with rigid or flexible low-cost
molds; low production rates
Processing of
composite materials Long cycle times; expensive operation; tooling costs depend on
process

5.5. Processing of Thermoplastics

Thermoplastics can be processed to their final shape by extrusion and moulding
processes.
5.5.1. Extrusion:
Extrusion is one of the fundamental shaping processes, for metals and ceramics as
well as polymers. Extrusion is a compression process in which material is forced to flow
through a die orifice to provide long continuous product. The cross-sectional shape is
determined by the shape of the orifice. The equipment is called as extruder.
Components
The main components are: Barrel, screw, heater and die.

Screw type Extrusion Process

Working Principle
1. Feed section, in which the stock is moved from the hopper port and preheated.
2. Compression section, where the polymer is transformed into liquid consistency, air
entrapped amongst the pellets is extracted from the melt, and the material is
compressed.
3. Metering section, in which the melt is homogenized and sufficient pressure, is
developed to pump it through the die opening.
Application

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Extrusion is widely used for thermoplastics but rarely for thermosets to mass produce
items such as tubing, pipes, hose, structural shapes such as window and door molding, sheet
and film, continuous filaments, and coated electrical wire and cable.
Advantages
1. High production volumes
2. Relatively low cost as compared with other molding process
3. Design flexibility
4. Short lead times
5. Coating of wire can be done to achieves desired properties
6. Continuous part can be produced
Disadvantages
1. Limited complexity of parts
2. Uniform cross section can only be produced

Extrusion Process Parameters

There are five important process parameters to be considered before extrusion
process:
1. Melting temperature of plastic
2. Speed of the screw
3. Extrusion pressure required
4. Types of die used
5. Cooling medium

5.5.2 Defects in Extrusion

The most common defect that occurs in extrusion are: Melt fracture, Sharkshin and
Bambooing.
Melt fracture: Stresses acting on the melt immediately before and during its flow
through the die are so high as to cause failure, manifested in the form of a highly irregular
surface on the extrudate. As suggested by Figure (a), melt fracture can be caused by a sharp
reduction at the die entrance, causing turbulent flow that breaks up the melt.
Sharkskin: Surface of the product becomes roughened upon exiting the die. As the
melt flows through the die opening, friction at the interface results in a velocity profile across
the cross section as shown in Figure (b). Tensile stresses develop at the surface as this
material is stretched to keep up with the faster moving center core. These stresses cause
minor ruptures that roughen the surface.
If the velocity gradient becomes extreme, prominent marks occur on the surface,
giving it the appearance of a bamboo pole; hence, the name bambooing for this more severe
defect.

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Extrusion Defects (a).Melt Fracture (b). Sharkskin (c) bambooing.

5.6 Injection molding

Injection molding is a process in which a polymer is heated to a highly plastic state
and forced to flow under high pressure into a mold cavity, where it solidifies. The molded
part, called a molding, is then removed from the cavity.
The production cycle time is typically in the range of 10 to 30 sec, although cycles of
1 min.
Classification of Injection molding machine
The injection molding machines are classified as follows:
(a). Based on injection unit
(i). Reciprocating screw type (ii). Plunger type
(b). Based on clamping unit
(i).Toggle type (ii). Hydraulic type (iii). Hydro mechanical type
Working:
1. The mold is closed and clamped.

Moulding cycle. (1) mold is closed, (2) melt is injected into cavity, (3) screw is retracted,
and (4) mold opens, and part is ejected.
2. A shot of melt, which has been brought to the right temperature and viscosity by
heating and the mechanical working of the screw, is injected under high pressure into
the mold cavity. The plastic cools and begins to solidify when it encounters the cold
surface of the mold. Ram pressure is maintained to pack additional melt into the
cavity to compensate for contraction during cooling.

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3. The screw is rotated and retracted with the nonreturn valve open to permit fresh
polymer to flow into the forward portion of the barrel. Meanwhile, the polymer in the
mold has completely solidified.
4. The mold is opened, and the part is ejected and removed.
Materials Used
Acrylonitrile Butadiene Styrene (ABS), Polyvinyl Chloride (PVC), Polypropylene (PP) etc.

Applications
This process can be used to manufacture thin walled plastic housing products which
require many ribs and bosses on the interior surfaces. These housings are used in a variety of
products including household appliances, electronics, and automotive dashboards. Other
common thin walled products include different types of open containers, such as buckets. It is
also used to produce several daily use items such as toothbrushes or small plastic toys, many
medical devices, including valves and syringes.
Advantages
1. Higher production rate
2. Close tolerances on small intricate parts
3. Minimum wastage of material
4. Complex geometry can be easily produced
Disadvantages
1. Tooling cost higher
2. High setup cost
3. Large undercuts can’t be formed

5.6.2 Other types of injection moulding:

Type of Injection System. a) screw preplasticizer (b) plunger type.

In plunger-type injection molding machines the plastic pellets are fed from a hopper
into the barrel. The heaters are used for melting the pellets. A plunger is used to inject the
melt into the mold. Plunger-type injection molding machines is shown in Figure (b).
5.7 Defects in Injection molding
The various defects occurring in injection molding process are listed below.
a. Shrinkage

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b. Short shots.
c. Flashing
d. Sink marks and voids
e. Weld lines

Shrinkage: Polymers have high thermal expansion coefficients, and significant

shrinkage can occur during cooling of the plastic in the mold. Contraction of crystalline
plastics tends to be greater than for amorphous polymers. Shrinkage is usually expressed as
the reduction in linear size that occurs during cooling to room temperature from the molding
temperature for the given polymer. Appropriate units are therefore mm/mm (in/in) of the
dimension under consideration.

Short shots: As in casting, a short shot is a molding that has solidified before
completely filling the cavity. The defect can be corrected by increasing temperature and/or
pressure. The defect may also result from use of a machine with insufficient shot capacity, in
which case a larger machine is needed.

Flashing: Flashing occurs when the polymer melt is squeezed into the parting surface
between mold plates; it can also occur around ejection pins. The defect is usually caused by
(1) vents and clearances in the mold that are too large; (2) injection pressure too high
compared with clamping force; (3) melt temperature too high; or (4) excessive shot size.

Sink marks and voids: These are defects usually related to thick molded sections. A
sink mark occurs when the outer surface on the molding solidifies, but contraction of the
internal material causes the skin to be depressed below its intended profile.

Weld lines: Weld lines occur when polymer melt flows around a core or other convex
detail in the mold cavity and meets from opposite directions; the boundary thus formed is
called a weld line, and it may have mechanical properties that are inferior to those in the rest
of the part. Higher melt temperatures, higher injection pressures, alternative gating locations
on the part, and better venting are ways of dealing with this defect.

5.8. Blow molding

 Blow molding is a molding process in which air pressure is used to inflate soft plastic
inside a mold cavity.
 Blow molding is accomplished in two steps: (1) fabrication of a starting tube of
molten plastic, called a parison (same as in glass-blowing); and (2) inflation of the
tube to the desired final shape.
Working:
 The parison is manufactured by extrusion process in the mould cavity.
 The parison is kept inside the mold cavity and then inflated by a blowing the air
inside. The parison get expanded and stick to the surface of the cavity. After cooling,
the mold is opened and the solidified part is taken out.
 The shape of the object to be produced, depends on the shape of the mold cavity.

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Extrusion Blow molding process.

Materials and Products
Blow molding is limited to thermoplastics. Polyethylene, polypropylene (PP),
polyvinylchloride (PVC), and polyethylene terephthalate.
Process Parameters
1. Amount of plastic material
2. Melting temperature of plastic material
3. Air pressure required
4. Cooling time
Applications
Different types of plastic products can be manufactured by this process such as
bottles in different shape and size, jars, and containers, ducting, fluid oil tanks, mugs, and
toys. Advantages
1. Low tooling cost
2. Fast production rates
3. Ability to mold complex part with uniform thickness
4. Little scrap generated
5. Large hollow shape can be produced
6. Produced parts can be recycle
Disadvantages
1. Limited to hollow parts
2. Thick parts can’t be manufactured

5.9. Rotational molding

Rotational molding uses gravity inside a rotating mold to achieve a hollow form. Also
called roto molding.

Working:
• A large relatively thin walled hollow parts are made.
• A measured quantity of polymer powder is placed in a thin walled metal mold.

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• The mold is closed and is rotated about two mutually perpendicular axis as it is
heated.
• This causes the powder to sinter against the mold walls, building up the wall
thickness of the component.
• At the end of the heating and sintering operations, the mold is cooled while it is still
rotating.
• Cooling is done in the outer surface by water or air.
• The rotation is stopped and the component is removed.
• To increase production rates three molds at the end of three arms joined together to
the centre spindle.
• Here no pressure is used so the parts are stress free.
• This process is possible to make upto 20000 liters capacity drum.
Process Parameters
1. The amount of powder
2. Heating temperature and time
3. Rotational speeds
4. Cooling rates

Material Used
Thermosets and thermoplastic material can be used, for example: low density
Polyethylene (LDPE), high density polyethylene (HDPE), polypropylene, and polyvinyl
chloride (PVC).
Applications
Additives for weather resistance, flame retardation can be incorporated. Products that
can be manufactured include storage tanks, bins and refuse containers, airplane parts, road
cones, footballs, helmets, and rowing boats.
Advantages
1. Allows complex mold split lines.
2. Allows molded threads and mold-in inserts.

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3. Allows a wide range of surface finishes (textured, smooth, or polished).

4. Very little waste.
5. Low residual stresses
6. Tooling is less expensive
7. Suitable for both low-volume prototypes and high-volume production runs
Disadvantages
1. Slow production speed.
2. It usually takes about one hour to complete the process
3. Lower precision
5.10. Thermoforming process
Thermoforming is a process in which a flat thermoplastic sheet is heated and
deformed into the desired shape.
Thermoforming consists of two main steps: heating and forming. Heating is usually
accomplished by radiant electric heaters, located on one or both sides of the starting plastic
sheet at a distance of roughly 125mm.

Vacuum Thermoforming Process Pressure Thermoforming process

Pressure Thermoforming
An alternative to vacuum forming involves positive pressure to force the heated
plastic into the mold cavity. This is called pressure thermoforming or blow forming.
The process sequence is similar to the vacuum forming, the difference being that the
sheet is pressurized from above into the mold cavity. Vent holes are provided in the mold to
exhaust the trapped air.

Mechanical Thermoforming
Mechanical thermoforming uses matching positive and negative molds that are brought
together against the heated plastic sheet, forcing it to assume their shape. In pure mechanical
forming, air pressure is not used at all. The process advantages are better dimensional control
and the opportunity for surface detailing on both sides of the part. The disadvantage is that
two mold halves are required; therefore, the molds for the other two methods are less costly.

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Mechanical Thermoforming process

Applications
 Thermoforming applications include large parts that can be produced from thicker
sheet stock.
 Examples include covers for business machines, boat hulls, shower stalls, diffusers for
lights, advertising displays and signs, bathtubs, and certain toys.
 Vehicle beds, dash panels, vehicle doors
Materials Used
Acrylic (PMMA), Acrylonitrile butadiene styrene (ABS), Cellulose acetate, Low density
polyethylene (LDPE), High density polyethylene (HDPE), Polypropylene (PP), Polystyrene
(PS), Polyvinyl chloride (PVC)
Advantages:
1. Extremely adaptive to design requirement
2. Rapid prototype development
3. Low initial setup costs
4. Low production costs
5. Less thermal stresses than injection molding and compression molding
6. Good dimensional stability
Disadvantages:
1. Poor surface finish
2. Parts may have non-uniform wall thickness.
3. All parts need to be trimmed
4. Ribs and bosses cannot be molded easily
5. Limited number of materials can be used
6. Very thick plastic sheets can’t be formed
5.11 Film blowing process:
This is the other widely used process for making thin polyethylene film for packaging.
It is a complex process, combining extrusion and blowing to produce a tube of thin film.
• Crystalline sharp melting polymer (like nylon) have very much suitable for the flim
productions by melt casting techniques.
• Initially the heated plastic powder is extruded by using extrude machines called
extruder.
• In this extrusion process the thin flim is produced.

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• Air is blown into the center of the extruded tube and causes it to expand in the radial
direction.
• Extension of the melt in both the radial and down-stream direction stops at the freeze
line (frost line) due to crystallization of the melt.
• The nip rolls collect the film, as well as sealing the top of the bubble to maintain the
air pressure inside. This process is used extensively with polyethylene and
polypropylene.
• After extruding the thin film is stretched by pulling rollers through the chilled
drum in the reeling wheel.
• The reeling wheel is used to make the flim roll.

Film blowing process

Applications:
Used to produce plastic bags
 Industrial packaging
 Consumer packaging
 Laminating flim
Advantages:
 It is a simple and high speed process to produce plastic covers

5.12 Compression molding

Compression molding is an old and widely used molding process for thermosetting
plastics. Its applications include rubber tires and various polymer matrix composite parts.
• In compression molding, a preshaped charge of material, premeasured volume of
powder, or viscous mixture of liquid-resin and filler material is placed directly into a
heated mold cavity that typically is around 200°C but can be much higher.

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• Forming is done under pressure from a plug or from the upper half of the die thus,
the process is somewhat similar to closed-die forging of metals.
• Pressures range from about 10 to 150 MPa.
• Compression molding is used mainly with thermosetting plastics.
• Curing times range from about 0.5 to 5 minutes, depending on the material and on
part thickness and shape.
• The thicker the material, the longer it will take to cure.

Compression Moulding process

Parameters of compression molding
a) The quantity of charge (molding material) put into the mold
b) Pressure of the molding process
Range of pressure 13.8 - 20.7 MPa.
c) Mold temperature
Temperature range 149⁰C- 191⁰C.
d) Cure time variables.
The period required to harden thermosetting material to partial and complete
polymerization is called cure time.
Application:
The parts made are dishes, handles, container caps, fittings, electrical and electronic
components, washing-machine agitators, and housings.
Advantages
 Production rate is high as the mold cycle time is in few minutes.
 Good surface finish with different texture and styling can be achieved.
 High part uniformity is achieved with compression molding process.
 Good flexibility in part design is possible.
 Extra features like inserts, bosses and attachment can be molded in during the
processing.
 Raw material wastage is minimum.
 Maintenance cost is low.
 Residual stresses are absent or negligible in the molded component.
 Twisting and shrinkage in product is reduced therefore dimensional accuracy is good.

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Disadvantages
 Due to expensive machinery and parts, the initial capital investment associated with
compression molding is high.
 The process is suitable for high production volume. It is not economical for making a
small number of parts or for prototyping applications.
 It is a labour intensive process.
 Sometimes secondary processing (trimming, machining) of product is required after
compression molding.
 Sometimes uneven parting lines are there.
 There is limitation on mold depth.

5.13 Transfer molding

Transfer molding process combines the principle of compression and transfer of the
polymer charge. In the transfer molding, polymer charge is transferred from the transfer pot
to the mold. The mold is cooled and molded part is ejected.
• This is an automated operation that combines compression-molding, injection-
molding, and transfer-molding processes.
• The uncured thermosetting resin is placed in a heated transfer pot or chamber and
after the material is heated, it is injected into heated closed molds.
• Depending on the type of machine used, a ram, plunger, or rotating-screw feeder
forces the material to flow through the narrow channels into the mold cavity at
pressures up to 300 MPa.
• This viscous flow generates considerable heat, which raises the temperature of the
material and homogenizes it.
• Curing takes place by cross-linking. Because the resin is in a molten state as it enters
the molds, the complexity of the parts and the dimensional control approach those of
injection molding.
There are two variants of the process. They are
(a) Pot transfer molding,
(b) plunger transfer molding

Pot transfer moulding

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In this process the charge is kept inside the pot and heated to molten state. Then the molten
charge is injected through a vertical sprue channel into the cavity. Then the mold is allowed
to cool and the part is taken out by a ejector pin.
Plunger transfer molding the charge is injected from a heated well by means of a
plunger through lateral channels into the mold cavity. Then the mold is allowed to cool and
part is ejected by the ejector pin.

Plunger transfer moulding

Process Parameters
1. Heating time
2. Melting temperature of the charge
3. Applied pressure
4. Cooling time
Materials Used
Generally, thermoset plastics (such as epoxy, polyester, phenol-formaldehyde, vinyl
ester, silicone) are processed by transfer molding process, but certain thermoplastic materials
can also be processed.
Applications
This process is widely used to encapsulate items such as integrated circuits, plugs,
connectors, pins, coils, and studs. It is suitable for molding with ceramic or metallic inserts
which are placed in the mold cavity. When the heated polymer fills the mold it forms bonding
with the insert surface. Transfer molding is also used for manufacturing radio and television
cabinets and car body shells.
Advantages
1. Fast setup time and lower setup costs 4. Design flexibility
2. Low maintenance cost 5. Dimensionally stable
3. Plastic parts with metal inserts can be 6. Uniform thickness of parts
made 7. Large production rate
Disadvantage:
1. Wastage of material
2. Production rate lower than injection molding
3. Air can be trapped in the mold

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5.14 Bonding of thermoplastics

lamination of Plastics

The thermo plastics are bonded by means of pressure and heat. The papers , cellulose, glass
fiber are used as a layers. For binding purpose we use synthetic resins. Bonding of
thermoplastics is called lamination it is done by two methods.

1) High Pressure Laminates

2) Low Pressure Laminates

The high pressure laminates we use pressure as 7 Mpa and Temperature around 150 °c. While
comparing to high pressure laminates low pressure laminates use very less pressure and heat.
This low pressure is also called as Reinforced plastics. Many materials like asbestos, cotton,
fiber are fabricated up of this laminates.

The lamination process of paper and glass fabrication it is dipped in the resin solution. The
oven makes the resin solution to dry by the help of rollers. These dried plastics are sized and
separated by cutting and it is pressed by press.

Stages of Lamination:

1) Dipped in the resin solution

2) Wet drying
3) Sized
4) Cutting
5) Pressing

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St. Joseph’s College of Engineering Manufacturing Processes 2023-2024

These reinforced plastics have high elastic stability and less in weight comparing to other
type of manufactured product.

Application:

1) Sheet metal making.

2) Aircraft parts.
3) Storage containers. 4) Light weight house hold articles.

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