UNIT V

Manufacturing of Plastic
Components
 Plastics
• Plastic is the general common term for a wide
range of synthetic or semi synthetic organic
amorphous solid materials suitable for the
manufacture of industrial products.
• Plastics are typically polymers of high
molecular weight, and may contain other
substances to improve performance and/or
reduce costs.
 Types of Plastics

• Plastics can be divided into two major categories:

1. Thermoset or thermosetting plastics. Once cooled and hardened,
these plastics retain their shapes and cannot return to their
original form. They are hard and durable. Thermosets can be used
for auto parts, aircraft parts and tires.
Examples include polyurethanes, polyesters, epoxy resins  and
phenolic resins.
2. Thermoplastics. Less rigid than thermosets, thermoplastics can
soften upon heating and return to their original form. They are
easily molded and extruded into films, fibers and packaging.
Examples include polyethylene (PE), polypropylene (PP) and
polyvinyl chloride (PVC).
 Thermoset or Thermosetting Plastics
1. Polyurethane Plastics :- Polyurethane plastics belong to the group that can be thermosetting.
Polyurethane is the only plastic which can be made in both rigid and flexible foams. The
flexible polyurethane foam is used in mattresses, carpets, furniture etc. The rigid polyurethane
foam is used in chair shells, mirror frames and many more. Due to the property of high
elasticity, some polyurethane plastics are used in decorative and protective coatings. The high
elasticity makes these polyurethane plastics resistant to a chemical attack.
2. Epoxy
Epoxies are used in numerous ways. In combination with glass fibers, it is capable of producing
composites that are of high strength and that are heat resistant. This composite is typically
used for filament wound rocket motor casings in missiles, in aircraft components, and in tanks,
pipes, tooling jigs, pressure vessels, and fixtures. Epoxies are also found in gymnasium floors,
industrial equipment, sealants, and protective coatings in appliances.
3. Phenolic
Phenolic plastics are thermosetting resins used in potting compounds, casting resins, and
laminating resins. They can also be used for electrical purposes and are a popular binder for
holding together plies of wood for plywood.
 Thermoplastics
1.Vinyl Plastics :-
Vinyl plastics belong to the thermoplastic group. Vinyl plastics are the sub-polymers of
vinyl derivatives.
These are used in laminated safety glasses, flexible tubing, molded products etc.
2.Polyacrylics Plastics :- Polyacrylics belong to the group of thermoplastics. Polyacrylics
are transparent and decorative. Polyacrylics plastics can be shaped in any form like the
windshields for airplane.
3.Polyvinyl Chloride
Polyvinyl Chloride, commonly referred to as PVC or vinyl, was first invented in Germany
around 1910. It didn't become a useful product in the United States, however, until the
late 1920s. It became particularly useful during World War II when it was used as a
substitute for rubber, which was in short supply. Polyvinyl Chloride is resistant to
abrasion and is both weather and chemical resistant. Today, it is commonly found in
upholstery, wall coverings, flooring, siding, pipe, and even apparel. In fact, vinyl is
perhaps the best known of all plastics.
4.Polyethylene Terephthalate (PETE) :- PETE is one the most recycled
plastic. It finds usage in various bottles like that of soda and cooking oil,
etc.
5.High Density Polyethylene (HDPE) :- HDPE is generally used in detergent
bottles and in milk jugs.
6.Polyvinyl Chloride (PVC) :- PVC is commonly used in plastic pipes,
furniture, water bottles, liquid detergent jars etc.
7.Low Density Polyethylene (LDPE) :- LDPE finds its usage in dry cleaning
bags, food storage containers etc.
8.Polypropylene (PP) :- PP is commonly used in bottle caps and drinking
straws.
9.Polystyrene (PS) :- PS is used in cups, plastic tableware etc.
 Characteristics of Plastics
• Mechanical properties
• Mechanical properties refer to displacement or breakage of plastic due to some mechanical
change such as applying some load.
Mechanical properties are dependent on the temperature, force (load), and the duration of time
the load is applied. It may also be affected by ultra-violet radiation when used outside.
• Thermal properties
• Thermal properties include heat resistance or combustibility.
Thermoplastic has a larger coefficient of thermal expansion or combustibility and a smaller
thermal conductivity or specific heat than other material such as metals.
• Chemical properties
• Chemical resistance, environmental stress crack resistance , or resistance to environmental
change are referred as chemical properties.
When a plastic contacts chemicals, there is some kind of change. After having a plastic in
contacted with chemicals under no stress for about a week, changes in appearance, weight and
size of the plastic are examined. Such changes are referred to as chemical properties.
• Electric properties
• Electric properties are also referred to as electromagnetic properties.
Electric properties include insulation, conductivity and electro-static
charges.
Due to their good insulation property, plastics are often used in
electric fields. However, plastics do have a defect; they are easily
electrified.
• Physical properties
• Specific gravity, index of refraction and moisture absorption are called
physical properties.
The specific gravity of the plastic is small, and it varies depending on
the character of high polymer , or thermal and mechanical treatment
of the plastic.
 Materials for Processing Plastics
Most Plastic resins have to be combined, compounded,
or otherwise chemically treated with processing
materials before they are ready for processing.
One of the following additions are usually employed;
1. Plasticizers
2. Fillers
3. Catalyst
4. Initiators
5. Dyes and Pigments
1. Plasticizers
i) Organic Solvents, resins, and even water are
used as plasticizers.
ii) These substances act as internal lubricants
improving flow of and giving toughness and
flexibility to the material
iii)Plasticizers are also used to prevent
crystallization by keeping the chains separated
from one another.
2. Fillers
i) Typical fillers which include wood floor,
asbestos fibre, glass fibre, cloth fibre, mica,
slate powders, may be added in high
proportion to many plastics essentially to
improve strength, dimensional stability, and
heat resistance.
3. Catalyst
These are usually added to promote faster and more complete
polymerization.
As such they are also called accelerators and hardeners.
4. Initiators
It is used to initiate the reaction, i.e., to allow polymerization to
begin
They stabilize the ends or reaction sites of the molecular chains.
H O is a common initiator.
2 2

5. Dyes and Pigments

These are added in many cases, to color the material to different
shades
 Plastic Processes
1. Moulding Process
2. Calendering Process
3. Thermoforming
4. Casting
5. Fabrication Process
 1. Moulding Processes
i. Compression Moulding
ii. Transfer Moulding
iii. Injection Moulding
iv. Jet Moulding
v. Extrusion
 Compression molding

• Compression molding is a method of molding

in which the molding material, generally
preheated, is first placed in an open, heated
mold cavity. The mold is closed with a top
force or plug member, pressure is applied to
force the material into contact with all mold
areas, while heat and pressure are maintained
until the molding material has cured.
Common plastics used in compression molding
processes include
• Polyester
• Polyimide (PI)
• Polyamide-imide (PAI)
• Polyphenylene Sulfide (PPS)
• Polyetheretherketone (PEEK)
• Fiber reinforced plastics
Compression Moulding Process
 Principle of working
• The compression molding starts, with an allotted amount of plastic
or gelatin placed over or inserted into a mold.
• Afterward the material is heated to a pliable state in and by the
mold.
• Shortly there after the hydraulic press compresses the pliable
plastic against the mold, resulting in a perfectly molded piece,
retaining the shape of the inside surface of the mold.
• After the hydraulic press releases, an ejector pin in the bottom of
the mold quickly ejects the finish piece out of the mold and then
the process is finished.
• Also depending on the type of plunger used in the press there will
or won't be excess material on the mold.
Factors affecting Compression Moulding

• Amount of material
• Heating time and technique
• Force applied to the mold
• Cooling time and technique
 Advantages
• Low initial setup costs
• Fast setup time
• Capable of large size parts beyond the capacity of extrusion
techniques
• Allows intricate parts
• Good surface finish (in general)
• Wastes relatively little material
• Can apply to composite thermoplastics with unidirectional tapes,
woven fabrics, randomly orientated fiber mat or chopped strand
• Compression molding produces fewer knit lines and less fiber-
length degradation than injection molding.
 Disadvantages
• Production speed is not up to injection
molding standards
• Limited largely to flat or moderately curved
parts with no undercuts
• Less-than-ideal product consistency
 Transfer molding
• Transfer molding is similar to compression molding in that
a carefully calculated, pre-measured amount of uncured
molding compound is used for the molding process.
• The difference is, instead of loading the polymer into an
open mold, the plastic material is pre-heated and loaded
into a holding champers called the pot.
• The material is then forced/transferred into the pre-
heated mold cavity by a hydraulic plunger through a
channel called sprue. The mold remains closed until the
material inside is cured.
Transfer molding
 Process in Transfer molding
1.The pre-heated, uncured molding compound is placed
in the transfer pot.
2.A hydraulically powered plunger pushes the molding
compound through the sprue(s) into the pre-heated
mold cavity. The mold remains closed until the
material inside is cured (thermosets) or cooled
(thermoplastics).
3.The mold is split to free the product, with the help of
the ejector pins.
4.The flash and sprue material is trimmed off.
 Plastic used in this Process
• Epoxy
• Polyester (Unsaturated)
• Phenol-formaldehyde Plastic (PF, Phenolic)
• Silicone rubber (SI)
 Advantages
• Product consistency better than compression
molding, allowing tighter tolerance and more
intricate parts
• Production speed higher than compression
molding
• Fast setup time and lower setup costs than
injection molding
• Lower maintenance costs than injection molding
• Ideal for plastic parts with metal inserts
 Disadvantages
• Wastes more material than compression
molding (scraps of thermosets are not re-
useable).
• Production speed lower than injection
molding
 Injection molding
• Injection molding is a manufacturing process
for producing parts from both thermoplastic
and thermosetting plastic materials.
• Material is fed into a heated barrel, mixed,
and forced into a mold cavity where it cools
and hardens to the configuration of the mold
cavity.
Conventional Single Stage Plunger Type
Single Stage Reciprocating Screw Type
Two stage plunger or Screw plasticiser type
 Process of Injection Moulding
• The process start with feeding plastic pellets in the hopper above the
heating cylinder of the machine.
• The resin falls into and is pushed along the heated tube by reciprocating
screw until a sufficient volume of melted plastic available
• This may take from 10 Sec to 6 min.
• The entire screw is then plunged forward to force the plastic into the
mould.
• Each shot may produce one or several parts, depending on the die used.
• The ram is held under pressure for a few seconds so that the moulded
part can solidify.
• It then retracts slightly, and the mould open
• Knockout pins eject the moulded piece.
 Applications
• milk cartons,
• Packaging
• bottle caps
• automotive dashboards
• pocket combs
• and most other plastic products available
today.
 Jet Moulding
• A modified version of the Injection moulding is
known as Jet Moulding Process.
• In this process the Plastic is preheated to about
93’C in the cylinder surrounding to nozzle.
• It is further heated as the plunger forces the resin
through the nozzle.
• After the mould has been filled, the nozzle is
cooled by running water to prevent
polymerization of the remaining material.
 Extrusion Moulding
• Extrusion is one of the most widely used
manufacturing processes across many industries.
• Essentially, it is not much different from squeezing
tooth paste out of the tube.
• Anything that is long with a consistent cross section is
probably made by extrusion.
• Common examples are spaghetti, candy canes,
chewing gums, drinking straws, plumbing pipes, door
insulation seals, optical fibers, and steel or aluminum
I-beams.
Extrusion Moulding
 Process
• The plastic extrusion molding process usually begins with
a thermoplastic in the form of pellets or granules.
• They are usually stored in a hopper (a funnel-shaped
receptacle) before they are delivered to a heated barrel.
• The molten plastic is then forced through a shaped
orifice, usually a custom steel die with shape of the cross
section of the intended part, forming a tube-like or rod-
like continuous work piece.
• Cooling of the work piece should be as even as possible.
 Plastics used in this process
• Acrylonitrile Butadiene Styrene (ABS)
• Acrylic
• Polycarbonate (PC)
• Polyethylene (PE)
• Polypropylene (PP)
• Polyester
• Polystyrene (PS)
• Polyvinylchloride (PVC)
 Advantages
• Low initial setup costs
• Fast setup time
• Low production costs
 Disadvantages
• Moderate production speed
• Average precision
• Limited to parts with a uniform cross section
 Thermoforming Process
• A plastic thermoforming process usually begins with a sheet of
thermoplastic material formed by the extrusion process using a slotted
die.
• Thin-gage materials (less than 1/16 inch thick) usually come in rolls; and
heavy-gage materials (up to 1/2 inch thick) normally come in sheets.
• The sheet of plastic material is first heated to become a flexible
membrane.
• This soft, rubber-like membrane is placed on the mold and stretched to
cover the entire surface.
• Vacuum, external air pressure, and mechanical forces are used to rid the
air bubbles and improve the surface quality.
• The plastic part remains in the mold until it solidifies. Excess material is
trimmed after the part is removed from the mold.
Thermoforming Process
 Process in Thermoforming
1.The plastic sheets used in thermoforming is usually made by extrusion.
The one-sided mold is usually made by aluminum.
2.This sheet of plastic material is first heated to become a flexible
membrane. It is soft but still not liquid or gooey.
3.The soft, rubber-like membrane is placed on the mold and stretched to
fit. Vacuum, external air pressure, and mechanical forces are used to rid
the air bubbles.
4.The plastic part is removed from the mold after it cools and hardens.
5.Trimming, drilling, and other finishing processes may be needed to
obtain the final product
Aluminum is the most common thermoforming mold material due to its
very high coefficient of thermal conductivity that allows speedy and
consistent cooling cycle.
 Plastics used in this process
• Acrylonitrile Butadiene Styrene (ABS)
• Acrylic
• Polycarbonate (PC)
• Polyethylene (PE)
• Polypropylene (PP)
• Polystyrene (PS)
• Polyvinylchloride (PVC)
 Advantages
• Low initial setup costs
• Fast setup time
• Low production costs
• Less thermal stresses than injection molding
and compression molding
• More details and better cosmetics than
rotational-molded products
 Disadvantages
• Geometries limited to thin shells or shallow
shapes
• One side of the product can be precisely
controlled by the mold dimensions while the
other side can not.