PIONEER DESIGN &

ENGINEERING PRIVATE
LIMITED

INTRODUCTIO
N TO PLASTICS

PREPARED BY: SUNIL SUDEVAN

 INTRODUCTION TO PLASTICS

PLASTICS
It is a common term used for a wide range of synthetic and semi synthetic
organic substances of high molecular weight, which can be formed into
desired shape by moulding, casting etc. They are Polymers.

Questions for Students:

Synthetic material ???

Semi Synthetic material ???
Polymer ??? Monomer??
 INTRODUCTION TO PLASTICS
Synthetic materials (Man made)
Material created by scientific processes.
Ex: Nylon
Semi-Synthetic Materials:
Prepared by chemical synthesis from natural materials
Ex: Milk of Rubber Tree(Rubber Sheet)
Polymer:
Is a Macromolecule composed of monomers.
Monomer:
Is a single molecule.

Monomer on Polymerization becomes a Polymer.

Ex: Ethylene becomes Polyethylene

Polymerization:
A chemical reaction in which two or more molecules combine to form
larger molecules.
 INTRODUCTION TO PLASTICS

Why We Prefer PLASTICS??

Low Cost
Ease of Manufacture
Versatility
Resistance to Water

Questions for Students:

Discussion about the industries using Plastics.

 INTRODUCTION TO PLASTICS
Advantages of Plastics:
Light Weight
Low Cost compared to metals.
Easily formed into desired shapes.
They have excellent finishing; possess good shock absorption capacity,
high strength as well as toughness

Questions for Students:

Find out more advantages of Plastics

 INTRODUCTION TO PLASTICS
Disadvantages of Plastics:
The poisonous gaseous product produced by the decomposition
plastic can causes CANCER
The recycling of plastic is not cost effective process and even
more expensive compare to its manufacturing.
Less dimensional stability over period of time(Creep Effect)
They have excellent finishing; possess good shock absorption
capacity, high strength as well as toughness

Questions for Students:

Find out more Disadvantages of Plastics

 INTRODUCTION TO PLASTICS
Classification of Plastics:
Based on Chemical Behaviour Plastics are classified into 2 Types

Thermoplastics
Thermoset Plastics
 INTRODUCTION TO PLASTICS
Classification of Plastics:
Thermoplastics:
Is a material which becomes Soft when heated and hard when
cooled. It can be reheated, reshaped, and frozen repeatedly.

They do not undergo chemical change

in their composition.

Questions for Students:

Read about the history of Thermoplastics

 INTRODUCTION TO PLASTICS
Classification of Plastics:
THERMOPLASTICS:

Examples:

ABS(acrylonitrile butadiene styrene)

Polycarbonate
Polyethylene
Polypropylene
Polystyrene
Poly vinyl Chloride

Questions for Students:

Find out More Examples and use.

 INTRODUCTION TO PLASTICS
Classification of Plastics:
Thermoset Plastics:

Thermosetting plastics can only be heated and shaped once.

Not recyclable.
Products used with heat (e.g. cooker knobs) are made using
Thermosetting.

Questions for Students:

Read about the history of Thermosetting Plastic .
 INTRODUCTION TO PLASTICS
Classification of Plastics:
THERMOSET PLASTICS:

Examples:

Epoxies
Phenolics
Polyimides
Polyester Plastics
Bakelite

Questions for Students:

Find out More Examples and uses.

 INTRODUCTION TO PLASTICS
Classification of Plastics:

Questions for Students:

Differences Between Thermo Plastics and Thermo Set

Plastics
PLASTICS
IN
AUTOMOTI
VE
INDUSTRY
PLASTIC IN AUTOMOTIVE INDUSTRY
 PLASTIC IN AUTOMOTIVE INDUSTRY

Advantages of Using Plastic in Automotive

Light Weight
Minimal corrosion, allowing for longer vehicle life
Design freedom, allowing advanced creativity and
innovation
Safety, comfort and economy
Recyclability.
Surface Finish
 PLASTIC IN AUTOMOTIVE INDUSTRY

Material used in a Typical Car and their weights

 PLASTIC IN AUTOMOTIVE INDUSTRY
Engineering Plastics & Commodity Plastics

Engineering plastics demonstrate good mechanical characteristics,

high dimensional stability, good chemical resistance and resistance to
wear.
Being more expensive, engineering plastics are produced in lower
quantities and tend to be used for smaller objects or low-volume
applications
Ex: ABS, Polycarbonates and Polyamides etc.

Commodity Plastics relatively low mechanical properties

and are of low cost.
Ex: Polyethylene, Polypropylene, Polystyrene, Polyvinyl
chloride.
 PLASTIC IN AUTOMOTIVE INDUSTRY
13 High Performance Plastic Materials Used in Automotive:

1. Polypropylene (PP)
2. Polyurethane (PUR)
3. Polyvinyl Chloride (PVC)
4. Acrylonitrile Butadiene (ABS)
5. Polyamide (PA)
6. Polystyrene (PS)
7. Polyethylene (PE)
8. Polyoxymethylene (POM)
9. Polycarbonate (PC)
10. Acrylic (PMMA)
11. Polybutylene Terephthalate (PBT)
12. Polyethylene Terephthalate (PET)
13. Acrylonitrile Styrene Acrylate (ASA)
 PLASTIC IN AUTOMOTIVE INDUSTRY
Plastic Materials Used in Automotive:
We are going to Discuss about only 5 Plastic Materials in detail. Its your
Task to find more about the remaining Materials(Properties, Applications
etc) used in Automotive.

Material We are going to Discuss:

1. Acrylonitrile Butadiene (ABS)

2. Polycarbonate (PC)
3. Polypropylene (PP)
4. Polyvinyl Chloride (PVC)
5. Polyethylene terephthalate (PET)
 PLASTIC IN AUTOMOTIVE INDUSTRY
Plastic Materials:

ABS (acrylonitrile butadiene styrene)

Thermoplastic
Amorphous material.
Terpolymer ( polymerizing Styrene and
Acrylonitrile in the presence of Polybutadiene)

Questions for Students:

Being Engineering Plastic, Cost is High for ABS. Still why ABS is
prefered?
 PLASTIC IN AUTOMOTIVE INDUSTRY
Plastic Materials:
ABS(acrylonitrile butadiene styrene)
Properties:

Strong, Rigid and Tough

Good Impact Resistance.
Good Electrical Insulation Properties
Good Surface Finishing
Light weight and easily Injection moulded
Good Dimensional Stability.
Questions for Students:
What you meant by Dimensional
Stability?
Disadvantages:
Relatively High Cost, Limited weathering Resistance, Heat resistance is low,
Flammable with high smoke generation.
 PLASTIC IN AUTOMOTIVE INDUSTRY
Plastic Materials:
ABS(acrylonitrile butadiene styrene)

Applications:

Automotive Trim Parts

Dashboards
Wheel Covers.
Headliners Density : 1.04 g/cc
Bumpers Shrinkage : 0.4-0.9 %

Questions for Students:

Find out other Parts made of ABS? What is Shrinkage?

 PLASTIC IN AUTOMOTIVE INDUSTRY
Plastic Materials:

Polycarbonate:

Thermoplastic
Good Mechanical Properties

Properties:

Low Weight
Impact resistance
Transparent
Dimensional Stability
 PLASTIC IN AUTOMOTIVE INDUSTRY
Plastic Materials:
Polycarbonate:

Disadvantages:

Poor Scratch Resistance

Subject to stress cracking
Cost is high
Poor chemical resistance

Questions for Students:

Find out more Disadvantages of PC?

 PLASTIC IN AUTOMOTIVE INDUSTRY
Plastic Materials:
Polycarbonate:
Density : 1.20 1.22 g/cc
Applications: Shrinkage : 0.5 0.7 %

Automotive Headlamps
Bullet Proof Windows

Questions for Students:

Find Out other Applications of PC? Compare between PC and ABS?

 PLASTIC IN AUTOMOTIVE INDUSTRY
Plastic Materials:
Commodity Plastics, so Cost is less.
Polypropylene:

Thermoplastic
Also known as Polypropene

Properties:

Low Density(weight saving)

Heat resistance
high stiffness
Dimensional Stability
Good hinge property
Good resistance to Water
 PLASTIC IN AUTOMOTIVE INDUSTRY
Plastic Materials:

Polypropylene:

Disadvantages:

tends to degrade from exposure to UV light

does not bond well with paint.
High flammability

Questions for Students:

Find out more Disadvantages of PP?

 PLASTIC IN AUTOMOTIVE INDUSTRY
Plastic Materials:

Polypropylene: Density : 0.91 g/cc

Shrinkage : 1.0 3.0 %
Applications:

Dashboard Components
Car Bumpers
Instrumental Panels
Door Trims

Questions for Students:

Find Out other Applications of PP?

 PLASTIC IN AUTOMOTIVE INDUSTRY
Plastic Materials:

Poly-Vinyl Chloride:

Third most widely produced synthetic plastic polymer, After PE and PP

Pure poly(vinyl chloride) is a white, brittle solid.
Amorphous.

Properties:

Low Cost and Light weight

Chemical resistance and resistant to weathering.
Abrasion Resistance
Fire resistant Questions for Students:
Good insulator
What you meant by Brittle?
What you meant by Abrasion?
 PLASTIC IN AUTOMOTIVE INDUSTRY
Plastic Materials:
Density : 1.1 1.45 g/cc
Poly-Vinyl Chloride:
Shrinkage : flexi 1.5 3.0 %
Rigid 0.2 0.4 %
Disadvantages:

It is called Poison Plastic, It releases Toxins when exposed to fire. It can

cause Health Problems.

Applications:

Upholstery
Dashboard
Door Panels
 PLASTIC IN AUTOMOTIVE INDUSTRY
Plastic Materials:

Polyethylene terephthalate (PET)

widely used for packaging foods and beverages.

light weight and easy to transport.

Properties:

Hard, stiff and dimensionally stable material.

Water resistance
Good Gas Barrier Properties
 PLASTIC IN AUTOMOTIVE INDUSTRY
Plastic Materials:

Polyethylene terephthalate (PET)

Density : 1.38 g/cc
Disadvantages:
Shrinkage : 1.5 %
Very susceptible to heat degradation.
if it is not recycled, it really never break down. It does break into tiny
pieces, dangerous to animals.

Applications:

Interior trims
 PLASTIC IN AUTOMOTIVE INDUSTRY
Plastic Materials:

Polyethylene terephthalate (PET)

Density : 1.38 g/cc
Disadvantages:
Shrinkage : 1.5 %
Very susceptible to heat degradation.
if it is not recycled, it really never break down. It does break into tiny
pieces, dangerous to animals.

Applications:

Interior trims
 PLASTIC IN AUTOMOTIVE INDUSTRY
Plastic Materials:
 PLASTIC IN AUTOMOTIVE INDUSTRY

FILLERS AND ADDITIVES:

Plastics are material that are composed not only of large polymeric
molecules, but also usually include some additional small molecule
materials that have been added to give the plastic some particular
characteristics. The characteristics of colour, flexibility, and rigidity, flame
resistance, weathering behaviour and process ability can be significantly
altered by the use of additives and fillers.

PLASTICIZERS:

Plasticizers are added to obtain flexibility and softness

 PLASTIC IN AUTOMOTIVE INDUSTRY

DIFFERENT MANUFACTURING PROCESSES FOR PLASTICS:

Injection Moulding.
Compression Moulding.
Blow Moulding.
Extrusion Moulding.
Thermoforming. Injection Moulding
Rotational Moulding.
Transfer moulding.
PLASTIC IN AUTOMOTIVE INDUSTRY
Injection Moulding
 PLASTIC IN AUTOMOTIVE INDUSTRY
MACHINE OPERATION SEQUENCE:
Injection Moulding
 PLASTIC IN AUTOMOTIVE INDUSTRY
PLASTIC DEFECTS

Most of the defects can be avoided in the design stage. As a designer it is

very good idea to be aware of your options in tooling and to consider
those while designing your part.

Some Main Factors Causing Defects:

Design of Product and Tool.

Material
Operating Condition i.e; Temperature, Pressure, Injection Speed and
Time
Management.
 PLASTIC IN AUTOMOTIVE INDUSTRY
PLASTIC DEFECTS
There are lots of defects in Plastics i.e; Burn marks, Sink mark, weld line,
bubbles, flash, Ejector Pin Marks, Warpage, Water mark, Short shot,
jetting, Voids, Flow Mark. etc

As per Design concern we are considering these

following Defects i.e
Sink mark
Warpage
Flash
Short Shot
Rat Hole
Voids
 PLASTIC IN AUTOMOTIVE INDUSTRY
PLASTIC DEFECTS

Sink Mark Stress

Voids Warpage
PLASTIC IN AUTOMOTIVE INDUSTRY
REFERENCES:

1. http://en.wikipedia.org/wiki/Plastic (cit. on 04.06.2015)

2. http://www.plasticsconverters.eu/markets/automotive (cit. on 04.06.2015)
3. http://www.rbex.ro/en/Business-opportunities/Large-Asian-manufacturer-of-plastic-injecte
d-components-for-the-automotive-industry-is-looking-to-buy-or-partner-with-a-Romanian-ba
sed-producer
(cit. on 04.06.2015)
4. http://www.motortrend.com/auto_shows/geneva/2010/1002_2011_volvo_s60 (cit. on
04.06.2015)
5. http://www.stephensinjectionmoulding.co.uk/revision/plastics/thermoplastics.html (cit. on
04.06.2015)
6. http://www.mr-dt.com/materials/plastics.htm (cit. on 04.06.2015)
7. http://www.dragoart.com/tuts/471/1/1/how-to-draw-a-jaguar-xf.htm (cit. on 04.06.2015)
8. http://www.mayuruniquoters.com/products.php?industryid=1#&gid=1&pid=3 (cit. on
12.07.2015)
9. http://www.psg-online.de/en/service/references/vakuolen/ (cit. on 23.07.2015)
10. http://www.plastictroubleshooter.com/ThePlasticTroubleshooter/sink_marks.htm (cit. on
23.07.2015)
THA
NK
YOU