INJECTION

MOLDING
• Injection molding is a manufacturing process for producing
parts from both thermoplastic and thermosetting plastic
materials.
• With injection molding, granular plastic is fed by gravity
from a hopper into a heated barrel.
• As the granules are slowly moved forward by a screw-type
plunger, the plastic is forced into a heated chamber, where it
is melted.
• As the plunger advances, the melted plastic is forced
through a nozzle that rests against the mold, allowing it to
enter the mold cavity through a gate and runner system.
• The mold remains cold so the plastic solidifies almost as
soon as the mold is filled.
Components of the Injection Molding Technique
• Injection Unit: a) melt the polymer.
b) to accumulate the melt in the screw chamber.
c) to inject the melt into the cavity,
d) to maintain the holding pressure during cooling.
• The Clamping Unit: a) to open and close the mold.
b) to hold the mold tightly to avoid flash during the filling and holding
• The Mold: a) Distribution of polymer melt into and through out the cavities.
b) Shapes the part.
c) Cools the melt and
d) eject the finished product.
[ Hold Pressure: the pressure is applied at the end of the initial injection strock and is
injected to complete the final filling of the mold and hold pressure remains active till
gate closure due to freeze off. ]
• Screw: Screw length to diameter should be important to have uniform
melt at higher output and also for uniform melt temperatures. Improved
performance comes from radius between the flights and root diameter of
the screw. It should be equal to or greater than the flight depth in the
respective zones.
• Drooling: When nozzles are moved away from the mold after injection
molding has been carried out, trickles of plastic from the sprue gate occur.
This trickle of plastic is generally called the drooling (trickling), which is said
to be caused by residual pressure stored in the sprue and runner.
• Screw decompression(Basically it moves the screw straight back to a set point to keep pressure out
of the tip of the barrel. This keeps stringing and such to a minimum) and reduction in nozzle
temperature can be used to control drooling into the mold. However, it is
necessary to identify and correct the cause of drooling.
• Some of the causes of drooling are too high melt temperature, wet resin,
long holdup time, polymer degradation, poor nozzle temperature, high
back pressure, and poor nozzle design.
Mold:
• The clamping unit is where the mold is attached.
• The mold can be closed or opened automatically and
• ejector pins are used to eject the molded object out of the
mold.
• The filling of the mold is accomplished by the flow of the
polymer melt under high injection pressure along the
nozzle, runners and gates into the cavities.
• Different elements of the mold:
1.Distribution Channel: a) sprue, b)Gate, c)Runner

2.Mold Cavity
3.Ejection System: ejector pin
4.Cooling System: water is circulated to remove heat.
 Injection Molding
‘Window’

- The temperature must be high enough to melt the polymer, but not too
high to cause thermal degradation.
- Pressure must be high enough to avoid short shot (i.e. partially filled
cavities), but not too high because we will have flash at the mold contact
surface.

Good molding
region
 runner : leads plastic from
sprue to cavity.

Sprue: leads plastic from

nozzle to mold
Gate: control flow of
plastic into the cavity,
 Injection Molding Cycle
Injection molding is a cyclic process:
1. Injection : The polymer is injected into the mold cavity.
2. Hold on time : Once the cavity is filled, a holding pressure is
maintained to compensate for material shrinkage.
3. Screw back : At the same time the screw retracts and truns, feeding
the next shot.
4. Cooling : The molding cools and resolidifies.
5. Mold Opening : Once the part is sufficiently cool, the mold opens and
the part is ejected.
6. The mold closes and clamps in preparation for another cycle.
Extrusion Molding
 Extrusion: Extrusion is a process, in which polymer is
propelled continuously along a screw through regions of
high temperature and pressure where it is melted and
compacted, and finally forced through a die shaped to give the
final product. Extruder represents a very complex machine to
process various types of polymeric materials and viscosities
under high temperature and pressure with very strong shear
forces and short residence time in the barrel.
• The screw extrusion process consists of three distinct zones, namely feed,
compression, and metering zone.
• Feed zone: The feed section picks up the finely divided polymer from a
hopper and propels it into the main part of the extruder.

• Compression zone: In the compression section, the loosely packed feed is

compacted, melted, and formed into a continuous stream of molten plastics.
Some external heat must be applied, but much is generated by friction.

• Metering section: The metering section contributes to uniform flow rate,

required to produce uniform dimensions in the finished product and builds
up sufficient pressure in the polymer melt to force the plastic through the
rest of the extruder and out of the die.

• For highly viscous polymer another additional working section is needed

before die as they only can be mixed by the application of shear stress
( their viscosity is too high to allow turbulence or diffusion to contribute
appreciably to mixing)
Screw: Screw design is used to
• improve distributive and dispersive mixing,
• alter the residence time distribution (RTD) of material inside the extruder to
meet processing requirements,
• separate processes such as melting, mixing, and devolatilization, which occur
along an extruder’s length.

Haul-Off Equipment: Smooth and glossy finish of the end products requires
the use of high quality belts, polishing rolls, or rubber rolls. Rubber rolls are
used in pipe, profile, and sheet extrusion. Either polished rolls or rubber rolls
are used, which depend on the end product finish. These haul-off should be
equipped with accurate speed controls for better results.
Extrusion Die: Die pressure is affected by flow rate of polymer melt, cross
section of the die, die temperature, and material viscosity. Controlling the
die pressure can achieve a maximum production rate and an optimal
application of extruder. The entrance angle in die should be optimum to
minimize the pressure drop. Die entrance angle has no considerable effect
on mechanical strength of the product, but the land length has some effects
Streamlined die with production will eliminate degradation problem or
make it insignificant. Therefore, streamlining the die surface and adaptor
promotes minimal drag on the material; hence, the polymer layer is not
spending excessive time in the machine.
 Breaker Plate:
The screens (a thick metal puck with many holes drilled
through it) are reinforced by a breaker plate
Functions of breaker plate:
- The pressure can exceed 5000 psi (34 MPa). The screen
pack/breaker plate assembly also serves to create back
pressure in the barrel.

- Back pressure is required for uniform melting and proper

mixing of the polymer.

-This breaker plate and screen pack combination also does

the function of converting "rotational memory" of the
molten plastic into "longitudinal memory".
 Types of Extruder: Two types of extruder.
1. Single Screw Extruder.
2. Twin Screw Extruder.
• Single- and twin-screw extruders differ in conveying mechanism.
• In single-screw extruder, the process is highly dependent on the frictional and
viscous properties of the material. In this extruder, the frictional and viscous
forces help in the melt conveying.  Single screw extruders are most popular for
their low cost, simple designs, and reliability. Typical sizes vary from 1 to 6 inch
(25 to 150 mm) and L/D ratio from 20 to 30 with 24 being most common. 
• Twin-screw extruders are designed to have positive conveying characteristics.
These extruders can be classified according to their geometrical configuration.
The polymeric material may be more or less trapped in compartments formed by
the two screws and barrel due to their full intermeshing nature of the twin screw.
Better the intermesh between the screws, the more positive conveying occurs. In
twin-screw extruder, the frictional and viscous forces have a minimal effect on
the conveying behavior. These extruders are preferred for higher output of better
quality extrudate from a machine of a given size or cost that have stimulated
from single-screw extruders.
Co-extrusion:
• The process of extruding two or more materials through a single die with two or
more orifices arranged so that the extrudates merge and weld together into a laminar
structure before chilling.
- Each material is fed to the die from a separate extruder.
- Co-extrusion can be employed in film blowing, free film extrusion, and extrusion
coating processes.
- This process is used to combine materials to provide properties that cannot be
obtained in a single polymer.
- For example a film for packaging food may consist of three layers imparting high
strength, low oxygen permeability and heat sealability
Coextrusion
Blown film process:
The molten plastic is pulled upwards from the die by a pair of
nip rolls high above the die.
• Around the die sits an air-ring. The air-ring cools the film as it
travels upwards.
• In the centre of the die is an air outlet from which compressed
air can be forced into the centre of the extruded circular
profile, creating a bubble.
• This expands the extruded circular cross section.
• The nip rolls flatten the bubble into a double layer of film.
• This film can then be spooled or printed on, cut into shapes,
and heat sealed into bags or other items.
• In sheet extrusion, these rolls not only deliver the necessary
cooling but also determine sheet thickness and surface texture
•
Compression
Molding
Large scale compression molding Trimming mold
press.
Introduction
Compression Molding is a process in which a molding polymer is squeezed
into a preheated mold taking a shape of the mold cavity and performing
curing due to heat and pressure applied to the material.

The method is used mostly for molding thermosetting resins (thermosets),

but some thermoplastic parts may also be produced by Compression
Molding.
The method uses a split mold mounted in a hydraulic press.
 Compression Molding process involves the following steps:

# A pre-weighed amount of a polymer mixed with additives and fillers (charge) is placed
into the lower half of the mold.

# The charge may be in form of powders, pellets, putty-like masses or pre-formed

blanks.

# The charge is usually preheated prior to placement into the mold. Preheated polymer
becomes softer resulting in shortening the molding cycle time.

# The upper half of the mold moves downwards, pressing on the polymer charge and
forcing it to fill the mold cavity.

# The mold, equipped with a heating system, provides curing (cross-linking) of the
polymer (if thermoset is processed).

# The mold is opened and the part is removed from it by means of the ejector pin.

# If thermosetting resin is molded, the mold may be open in hot state – cured
thermosets maintain their shape and dimensions even in hot state.

# If thermoplastic is molded, the mold and the molded part are cooled down before
opening.
Process Description
Parameters

1.The quantity of charge(molding material)put into the mold

 2.Pressure of the molding process

• Range of pressure 2000-3000 psi(13.8-20.7 MPa)

3.Mold temperature
• Temperature range 300ºF to 375ºF (149⁰C- 191⁰C).

4.Cure time variables.

• The period required to harden thermosetting material to partial and complete
polymerization is called cure time.
Press
Mold
 Breathing: The two halves pinch the material on the land. The mold halves
are closed first and then just for a fraction of a second it is opened and again
closed down. This is called breathing.
It helps in removing any trapped gas or volatiles in the molten resin.

Flash : also known as flashing, is excess material attached to a molded, forged,

or cast product, which must usually be removed. ... Proper design of mold parting
surfaces can reduce or eliminate flash. Molding flash can be caused from old or
worn mold cavities that no longer fit tightly together.

Materials commonly processed by Compression

Molding are:
Epoxies (EP)

Urea Formaldehyde (UF)

Melamine Formaldehyde (MF)

Phenolics (PF)
  Materials used in this process

A) Thermosetting polymers:

B) Fiber reinforced composite

C) Thermoplastic:
• Ultra High Molecular Weight Polyethylene (UHMWPE)
• Long Fiber reinforced Thermoplastics
• Advantages
• 1Tooling costs are low because of the simplicity of the usual molds.
• 2 Little material is wasted since there are usually no sprues or runners
[when not compared to runnerless injection molding
• 3 TSs(Thermoset) when compared to (thermoplastic)TPs are not subject to
retaining internal stresses after being cured.
• 4Mechanical properties remain high since material receives little
mastication in the process and when using reinforcements they are literally
not damaged or broken.
• 5Less clamping pressure required than in most other processes.
• 6Capital equipment is less costly.
• 7Wash-action erosion of cavities is minimal and mold maintenance is low
since melt flow length is short.
• Limitations:
• 1Fine pins, blades, and inserts in the cavity can become damaged as the
press closes when cold material is used in the cavities.
• 2Complex shapes may not fill out as easily as by the transfer or injection
molding processes.
• 3Extremely thick and heavy parts will cure more slowly than in transfer or
injection molding, but preheating preforms or powder can shorten these
cures.
• 4Thermosets with their low viscosity will produce flash during their cure
that has to be removed.
Thermoforming
• Thermoforming is a process of shaping flat
thermoplastic sheet which includes two stages:
softening the sheet by heating, followed by forming it
in the mold cavity.

• Elastomers and Thermosets can not be formed by the

Thermoforming methods because of their cross-linked
structure – they do not soften when heated.
• Thermoplastics which may be processed by the
thermoforming method are:

• Polypropylene (PP)
• Polystyrene (PS)
• Polyvinyl Chloride (PVC)
• Low Density Polyethylene (LDPE)
• High Density Polyethylene (HDPE)
• Cellulose Acetate
• Polymethylmethacrylate (PMMA)
• Acrylonitrile-Butadiene-Styrene (ABS)
Thermoforming is widely used in the food packaging industry for
manufacturing
• ice cream and
• margarine tubs,
• meat trays microwave containers,
• snack tubs sandwich packs etc.

Thermoforming is also used for manufacturing some

• pharmaceutical and electronic articles,
• small tools,
• toys,
• boat hulls,
There are three thermoforming methods, differing in the technique
used for the forming stage:

• Vacuum Thermoforming
• Pressure Thermoforming
• Mechanical Thermoforming
Vacuum Thermoforming
• The process involves shaping a preheated thermoplastic sheet by
means of vacuum produced in the mold cavity space.
• The atmospheric pressure forces the soft sheet to deform in
conformity with the cavity shape.
• When the plastic comes into the contact with the mold surface it
cools down and hardens.
Pressure Thermoforming
• The process involves shaping a preheated
thermoplastic sheet by means of air pressure.
• The air pressure forces the soft sheet to deform in
conformity with the cavity shape.
• When the plastic comes into the contact with the
mold surface it cools down and hardens.
Mechanical Thermoforming
• The process involves shaping a preheated thermoplastic sheet by
means of a direct mechanical force.
• A core plug (positive mold) forces the soft sheet to fill the space
between the plug and the negative mold.
• The process provides precise dimensional tolerance and surface
detailing.
Comparison of thermoforming and injection
molding
The advantages of thermoforming over injection molding are lower
equipment costs, ability to make thinner walls, ability to make large
surface area parts, shorter possible lead time from conception to
production, and less costly model changes due to less expensive tolling.

The disadvantages compared to injection molding are first - it is a two-

step process (extrusion plus thermoforming); more scrap and regrind is
generated; there tends to be more part to part variation; wall thickness
is less adjustable and more variable; lower surface gloss; less part
complexity. 
Transfer
molding
Transfer Molding (Resin Transfer Molding) is a
process in which

•a pre-weighed amount of a polymer is preheated

in a separate chamber (transfer pot)

•then forced into a preheated mold through a

sprue,

•taking a shape of the mold cavity and

•performing curing due to heat and pressure

applied to the material.
The method combines features of both
Compression Molding (hydraulic pressing and the
same molding materials - thermosets) and
Injection Molding (ram-plunger and filling the mold
through a sprue).

Transfer Molding process involves the following

steps:
1. A pre-weighed amount of a polymer mixed with
additives and fillers (charge) is placed into the
transfer pot.
2. The charge may be in form of powders, pellets,
putty-like masses or pre-formed blanks.
3. The charge is heated in the pot where the
polymer softens.
4.The plunger, mounted on the top plate, moves
downwards, pressing on the polymer charge and forcing
it to fill the mold cavity through the sprue.
5.The mold, equipped with a heating system, provides curing
(cross-linking) of the polymer (if thermoset is processed).
6. The mold is opened and the part is removed from it by
means of the ejector pin.
7. If thermosetting resin is molded, the mold may be open in
hot state – cured thermosets maintain their shape and
dimensions even in hot state.
8. If thermoplastic is molded, the mold and the molded part
are cooled down before opening.
9. The scrap left on the pot bottom (cull), in the sprue and in
the channels is removed. Scrap of thermosetting
polymers is not recyclable.
• Transfer molding is similar to compression molding; however, the material
is first placed in a transfer chamber prior to entering the mold. As in
compression molding, thermosets that are cross-linked with heat are used
for transfer-molding applications. Multiple cavities can be used within
transfer molding since the material is entering the mold after the mold is
closed.
• Since runners and sprues are present, shear is created. This facilitates heat
needed for crosslinking and flow to the cavities. Transfer-molding machines
are also generally positioned with the molds opening vertically. Since the
mold is closed and clamped prior to the material entering the mold, there is
no presence of flash with transfer molded parts.
• The dimensions of the final parts are very accurate due to the flow of the
polymer being gated. Another advantage is that the cure time is faster since
there is the presence of shear flow, which creates heat. Inserts can also be
used to create more complex parts than can be created by compression
molding.
• Materials commonly processed by transfer Molding are:
• Epoxies (EP)
• Unsaturated Polyesters (UP)
• Phenolics (PF)
• Vinylester
Blow Molding
•Blow molding process is used to make plastic bottles, jars,
and other hollow objects. The process is similar to the old art
of glass blowing and is a batch process
• Blow molding is a two-step process in which first a hollow
tube, normally referred to as parison or preform, is produced
from molten plastics, then the second step of inflating it into
desired shape is performed inside a mold.
• The inflated parison takes the shape of the mold and retains
it upon cooling.
• The resulting products are tough, lightweight, and have large
volume-to-weight ratio.

•Products range from simple radially symmetric bottles to

complex items with handles or sculpted surfaces. Common
examples are milk jugs, gas cans, shampoo containers, liquid
storage tanks, toys, ducts, water bottles, and soda bottles
• Extrusion Blow Molding In EBM plastics materials are
extruded into a hollow tube (parison).
• When the parison reaches a desired length, the two
halves of the mold close on the parison, holding the
neck end open and pinching the sides and bottom.
• Compressed air from the blown pin then inflates the
parison inside the mold cavity. Upon cooling the mold
is opened and the part is trimmed to obtain the
finished part.
• Injection Blow Molding IBM process uses Injection Molding
rather than extrusion to produce the precursor. The precursor
is generally known as preform rather than a parison.
• The equipment has an IM unit and a blowing station, and the
mold cores are mounted on a rotary table. In this process first
a preform is injection molded onto a hollow core pin or
mandrel. While the preform is still hot and plastic, the injection
mold is opened and the preforms with the hollow core pin are
rotated and placed in a larger mold on the blowing station
where it is inflated into the desired shape Upon cooling the
core pin or mandrel is removed. This process results in a
precise blow-molded neck and not a pinch-off scrap. The
process is limited to producing integral handles, view strips,
and multiwall construction.
• Stretch Blow Molding SBM produces parts with biaxial
molecular alignment. In this process the molded preform is
heated abo The heated preform is then mechanically stretched
with a core rod and at the same time it is blown with
compressed airThe stretching action strain hardens the
material thereby increasing the strength.
• The resultant molecular orientation and strain hardening
allows the materials to resist deforming under pressure, and
provides better gloss and higher burst pressure. Thus the
products could be produced with less material than if they
were manufactured using standard blow molding process. This
process is very common for the polyethylene (PE)
terephthalate carbonated drink bottles. ve the glass transition
temperature.
• Optimization Operating parameter is considered to optimize
the main challenge for the blow molding process. This is due to
the high sensitivity of the process to the smallest variations in
the settings and/or the surrounding environment. After a
thorough investigation of the existing processes, the factors
that affect the volume and mass of the produced bottles were
identified as
• • screw speed,
• • melt temperature,
• • blow pressure,
• • blowing time,
• • mold temperature,
• • cooling time.