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Plastics Processing

There are several common plastic processing techniques described in the document, including extrusion, injection molding, blow molding, vacuum forming, compression molding, calendering, and rotational molding. Extrusion is used to produce solid or hollow products with a constant cross-section through the continuous process of heating and forcing plastic through a die. Injection molding involves melting plastic and injecting it into a mold under pressure to form complex shapes. Blow molding uses compressed air to inflate a hollow plastic tube against a mold to form bottles or hollow containers.

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347 views19 pages

Plastics Processing

There are several common plastic processing techniques described in the document, including extrusion, injection molding, blow molding, vacuum forming, compression molding, calendering, and rotational molding. Extrusion is used to produce solid or hollow products with a constant cross-section through the continuous process of heating and forcing plastic through a die. Injection molding involves melting plastic and injecting it into a mold under pressure to form complex shapes. Blow molding uses compressed air to inflate a hollow plastic tube against a mold to form bottles or hollow containers.

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Plastic Processing

Extrusion

Compression Moulding

Injection Moulding

Calendering

Blow Moulding

Strip Heating

Vacuum Forming

Rotational Moulding

Extrusion

Extrusion
Continuous process used to produce both solid and hollow products that have a
constant cross-section. E.g. window frames, hose pipe, curtain track, garden
trellis.
Thermoplastic granules are fed from a hopper by a rotating screw through a
heated cylinder.
The tapered screw compacts the plastic as it becomes elasticised. The die which
is fitted to the end of the extruder barrel determines the cross-section of the
extrusion.
Thicker cross-sections are extruded more slowly as more time is required for the
initial heating and subsequent cooling of the larger quantities of material which
are involved. As the extrusion leaves the die it is cooled by passing through a
cooling trough (below) containing cold water.

Materials used in Extrusion


This extrusion is part of a window seal made from
thermoplastic elastomer (TPE).

Injection Moulding
Powder or granules from a hopper
into a steel barrel with a rotating
screw. The barrel is surrounded by
heaters The screw is forced back as
plastic collects at the end of the
barrel .
Once a sufficient charge of melted
plastic has accumulated a hydraulic
ram forces the screw forward
injecting the thermoplastic through
a sprue into the mould cavity.

Injection Moulding
Pressure is kept on the mould until
the plastic has cooled sufficiently
for the mould to be opened and the
component ejected.

Materials used
Normally thermoplastics are used in this process although a
few thermosetting plastics can also be injection moulded.
Toy made from high impact polystyrene (HIPS).

Blow Moulding

1. A hollow length of plastic,


called a parison, is extruded
down between the two halves of
the mould.

2. The mould closes.

Blow Moulding

3. Compressed air is blown into


the inside of the parison which
inflates it, pushing the soft plastic
hard against the cold surfaces of
the mould.

4. The mould is then opened the


moulding ejected and the waste
(called flash) is trimmed off
with a knife.

Materiasl used in blow moulding


High density polyethylene (HDPE) and low density polyethylene
(LDPE) are both commonly used for blow moulding as are other types
of thermoplastics. The thermoplastic used in blow moulding needs to be
more viscous (flow less easily) than that used for injection moulding as
the parison must retain its form before the mould closes around it.
Used extensively to make bottles and other lightweight , hollow parts

Vacuum Forming

1. Mould is attached to a platen


(support plate). The platen and
mould are then lowered and a
rigid thermoplastic sheet material
is clamped onto an air tight
gasket and usually heated from
above.

2. Once the thermoplastic sheet is


softened enough (reaches a plastic
state) then air is blown in to raise the
sheet in a slight bubble before the
platen is raised bringing the mould
into contact with the plastic.

Vacuum Forming

3. trapped air remaining between


the platen and the heated plastic
sheet is then evacuated by a
vacuum pump. Atmospheric
pressure acting over the top surface
completes the forming process by
pressing the plastic sheet onto the
mould.

4. Once the plastic sheet has cooled


down to below it's freeze point the air
flow is reversed to lift the forming off
the mould and the mould lowered

Materials used in Vacuum forming


Many types of thermoplastics are suitable for vacuum
forming. The most popular is High Impact Polystyrene
(HIPS). It is relatively cheap, comes in a wide range of
colours and is easy to form. This process is used to
manufacture a variety of products in thermoplastic
materials. These products range in size from garden pond
liners to food trays used in supermarkets.

Compression Moulding

1. The mould is charged with a


measured amount of powder or
granules ready to be compressed.
Sometimes plastic charge is first
compacted into a shape called a
preform.

2. When the two halves of the mould


are brought together the plastic
material is forced under compression
to flow rapidly around the cavity. heat
from the platens causes the plastic to
cure resulting in a permanent change
in shape.

Compression Moulding
The component is
ejected from the
mould and any
excess material
formed at edges
(flash) is removed.
Materials used.
Typical thermosetting plastics used in
compression moulding are urea formaldehyde
and phenol formaldehyde.

Calendering

Calendering
Involves rolling out a mass of premixed plastics material between large rollers
to form a continuous and accurately sized film.
The process begins with the ingredients being blended and fluxed in a mixing
mill at approx.100C. Nip rollers control the thickness of the sheet material
can be gradually reduced in thickness. Rolls of semi-rigid PVC which will be
used to manufacture transparent A4 folder 'pockets'.
Materials used
The main material used is PVC, others include ABS and cellulose acetate.
PVC ranges from flexible to rigid and the final product is composed of a
number of basic materials which must be combined in a uniform mixture of
measured ingredients. These ingredients include a resin of a specified
molecular weight, stabilisers, lubricants, reinforcing materials, colorants and
plasticisers.

Rotational Moulding
1. A measured weight of
thermoplastic is placed inside a
cold mould. The mould is then
closed and moved into an oven
chamber

2. heated to a temperature of 230400 C whilst being rotated around


both vertical and horizontal axes.
As it rotates the mass of powder at
the bottom of the mould fuses and
sticks to the mould surface.

Rotational Moulding
3. the mould moves into
a cooling area or
chamber where it is
cooled by air or water
jets.
4. The hollow moulding
can be removed as soon
as it is cool enough to
hold its shape.

Materials used
90% of rotational mouldings are made from polyethylene
(PE), used mainly to manufacture hollow shaped products
such as footballs, road cones and storage tanks up to 3m
capacity.

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