Session-12-Polymer Manufacturing

PEMP- EMM2512
Polymer Manufacturing
Session – 10
Session Speaker
Mr. Harsha. G . Patil
Asst. Professor
AAE, Department
 M.S Ramaiah School of Advanced Studies - Bangalore 1

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Session Objectives
• By the end of the session the delegate

should be able to understand
– Different “Manufacturing Techniques” used
for various types of polymers
– Analyse the selection of manufacturing
techniques for different components.

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Unit Operations in Polymer Processing

Thermoplastic and thermoset melt processes are broken into:
•Preshaping
•Shaping
•Shape Stabilization
Preshaping steps:
–Solids handling and conveying: most processes usually
involve feed in particulate form
–Plastication: Creation of a polymer melt from a solid
feed.
–Mixing: often required to achieve uniform melt
temperature or uniform composition in compounds
–Pumping : The plasticated melt must be pressurized and
pumped to a shaping device
PEMP- EMM2512
Unit Operations in Polymer Processing

Shaping:
The polymer melt is forced through the shaping
devices to create the desired shape.
The flow behavior (rheology) of polymer melts
influences the design of the various shaping devices, the
processing conditions and the rate at which the product
can be shaped.
Shape stabilization:
–Involves the solidification of the polymer melt in the
desired shape, through heat transfer

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Thermoplastic Forming

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Injection Moulding
The injection molding machine converts granular or pelleted raw plastic into
final molded parts via a melt, inject, pack, and cool cycle.
Zones in Injection Moulding Machine
Heaters for melting

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Injection Moulding
• Most important process and ideally suited to manufacture mass
produced parts of complex shapes requiring precise dimensions.
• Is used for numerous products, ranging from boat hulls and lawn
chairs, to bottle cups. The components of the injection molding
machine are the plasticating unit, clamping unit and the mold
• The plastic resin is preheated in a drier to remove moisture and
is introduced into the injection moulding machine via a Hopper.
• The injection moulding machine consists of a heated barrel
equipped with a reciprocating screw driven by a hydraulic or
electric motor
• The screw feeds the molten polymer into a temperature
controlled split mould via a channel system of gates and runners.

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Injection Moulding Process

• The screw melts (plasticises) the polymer, and also acts as a
ram during the injection phase.
• The screw action also provides additional heating by virtue
of the shearing action on the polymer
• The polymer is injected into a mould that defines the shape
of the moulded part.
• The pressure of injection is high, dependant on the material
being processed; it can be up to one thousand atmospheres
• Moulds are manufactured from steels, (which can be
hardened and plated), and Aluminium alloys and involve
many machining operations, polishing and assembly

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Typical Materials Used : Acrylonitrile-

Butadiene-Styrene, Nylon, Polycarbonate,
Polypropylene, Polystyrene, PVC
Typical Products Produced : Power-tool
housings, Telephone handsets, Safety
helmets, Television cabinets
Injection Moulding (Gas Assisted ) :

Enhanced quality, reduced cycle times and
component weight reductions can be
achieved by gas assisted injection
moulding.

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Extrusion
•Widely used method along with injection molding.
•The Plastic raw material is both melted and traversed along by
the action of heated rotary screws.
•It is a continuous process and is thus able to manufacture long
lengths of a product.
•Ideal for such applications as pipes and gaskets. However very
often the continuous extrusion is cut into application lengths

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Extrusion
The forcing of a plastic or molten material through a shaped die

by means of pressure.

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Blow Molding
To form hollow shapes - do not require a homogeneous thickness

distribution.
Air injected – heated polymer expands in a fairly uniform
thickness of desired shape
HDPE, LDPE, PE, PET and PVC
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Extrusion Blow Moulding

• The blow moulding machine is based on a standard extruder barrel and
screw assembly to plasticise the polymer.
• The molten polymer is led through a right angle and through a die to
emerge as a hollow (usually circular) pipe section called a parison.
• When the parison has reached a sufficient length a hollow mould is
closed around it. The mould mates closely at its bottom edge thus
forming a seal.
• The parison is cut at the top by a knife prior to the mould being moved
sideways to a second position where air is blown into the parison to
inflate it to the shape of the mould.
• After a cooling period the mould is opened and the final article is ejected
• To speed production several identical moulds may be fed in cycle by the
same extruder unit
• The process is similar to that used for producing glass bottles, in that the
molten material is forced into a mould under air pressure.

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Injection Blow Moulding Process

• The process is divided in to three stages
Injection
The injection blow moulding machine is based on an
extruder barrel and screw assembly which melts the
polymer.
• The molten polymer is fed into a manifold where it is
injected through nozzles into a hollow, heated preform
mould.
• The preform mould forms the external shape and is clamped
around a mandrel (the core rod) which forms the internal
shape of the preform.
• The preform consists of a fully formed bottle/jar neck with a
thick tube of polymer attached, which will form the body
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Injection Blow Moulding Process

Blowing
 The preform mould opens and the core rod is rotated and clamped into the
hollow, chilled blow mould.
 The core rod opens and allows compressed air into the preform, which
inflates it to the finished article shape.
Ejection
 After a cooling period the blow mould opens and the core rod is rotated to
the ejection position.
 The finished article is stripped off the core rod and leak-tested prior to
packing.
 The preform and blow mould can have many cavities, typically three to
sixteen depending on the article size and the required output.
 There are three sets of core rods, which allow concurrent preform injection,
blow moulding and ejection

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Injection Blow Moulding : The main applications
are bottles, jars and other containers. The Injection
blow moulding process produces bottles of superior
visual and dimensional quality compared to extrusion
blow moulding with no flash
Typical Materials Used : Polyethylene (Low
Density), Polypropylene, Polyethylene –
Terephthalate, Polyvinyl chloride
Typical Products Produced : Bottles, Jars, Roll-on
containers, toys
Injection Stretch Blow Moulding : Injection stretch

blow moulding is used for the production of high
quality containers.
Typical Materials Used Polyethylene - Terephthalate
Typical Products Produced Carbonated and soft
drink bottles, Agrochemical containers, Bathroom
and toiletry products, Cooking oil containers,

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Thermoforming
Important Secondary Operation
Sheets/films in 3 dimensions.
Sheets clamped to an edge and
heated– softens and sags
Drawn in contact with mold of
vacuum, cooled in contact
Machine guards etc

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Thermoforming
The plastic sheet is heated slightly above the Tg for amorphous
polymers, or slightly below M.P., for semi-crystalline polymers and
then shaped into the cavity over the tool by vacuum or plug assist.
•Amorphous materials are preferred, because they have a wide
rubbery temperature range above the Tg. The polymer is easily
shaped, but still has enough “melt strength” to hold the heated
sheet without sagging. Temperatures about 20-100°C above Tg are
used.
•Used for refrigerator liners, shower stalls, bathtubs and various
automotive parts.
•Most common materials are Polystyrene (PS), Acrylonitrile-
Butadiene-Styrene (ABS), PVC, PMMA and Polycarbonate (PC)

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Thermoforming : Thermoforming has close
similarities with Vacuum Forming except that
greater use is made of air pressure and plug assisted
forming of the softened sheet. Only thermoplastics
sheet can be processed by this method.
Typical Products Produced Meat Trays,
Microwave & Deep Freeze Containers, Ice Cream
and Margarine Tubs, Delicatessen Tubs, Snack
Tubs, Bakery and Patisserie packaging, Sandwich
Packs and Vending Drink Cups
Extrusion Blow Moulding : Used for the
production of hollow objects in large
quantities. Obvious application are bottles and
similar containers.
Typical Materials Used Polypropylene,
Polyethylene, Polyethylene – Terephthalate,
Polyvinyl chloride
Typical Products Made Bottles and containers,
Automotive fuel tanks, Venting ducts, Watering
cans
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Calendering
Thermoplastic and thermosets.

Gap b/w the last pair of heated
rolls determines the thickness
of the sheet.
Elastomer sheets, gaskets, vinyl
flooring tiles etc.

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Rotational Molding
Large hollow containers – fuel
(Rotamoulding or Rotomoulding) tanks, water tanks.
By using additional post-
moulding operations, complex
components can be produced.
This provides the following
advantages:
–Economically produced large
products
–Minimum design constraints
–Stress-free products
–No polymer weld lines
–Comparatively low mould costs

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Rotational Moulding
The Rotational Moulding process is essentially split into four operations
Charging Mould
 A pre-determined amount of polymer powder is placed in the mould, the
mould is closed, locked and loaded into the oven
 The powder can be pre-compounded to the desired colour
Heating & Fusion
• Once inside the oven, the mould is rotated around two axis, tumbling the
powder – the process is not a centrifugal one.
• The speed of rotation is relatively slow, less than 20 rev/min.
• The ovens are heated by convection, conduction and, in some cases,
radiation
• As the mould becomes hotter the powder begins to melt and stick to the
inner walls of the mould, it gradually builds up an even coating over the
entire surface.

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Rotational Moulding
• Cooling
When the melt has been consolidated to the desired
level, the mould is cooled either by air, water or a
combination of both.
• The polymer solidifies to the desired shape.
• Unloading/Demoulding
When the polymer has cooled sufficiently to retain
its shape and be easily handled, the mould is opened
and the product removed.
• At this point powder can once again be placed in the
mould and the cycle repeated.
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Expanded Polystyrene Moulding

• The major application of Expanded polystyrene (EPS) is for protective
packaging for consumer electronic products and white goods.
• Its excellent thermal insulation and mechanical protection properties
make it ideal to package fish and other foodstuffs
• It is used in the manufacture of children's car seats and cycling helmets,
where its protective qualities, strength and shock-absorbency are vital
• Unlike other thermoplastic processes, the production of EPS products
requires that the raw materials be pre-conditioned prior to their final
"tooled" moulding process
• The raw material (also known as "expandable polystyrene" or "bead")
has a spherical shape and is similar to sugar in appearance.
• The conversion process is carried out in three stages - pre-expansion,
maturing and final forming

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Pre-expansion
 The tiny spherical polystyrene beads are expanded to about 40 times their
original size using a small quantity of pentane (typically 5% by weight)
as a blowing agent.
 It involves the heating of beads, using a flow of steam, which causes the
blowing agent to boil and thus a honeycomb of closed cells is formed.
Maturing
 As the material cools the pentane liquefies and a partial vacuum is
formed inside the bead.
 The beads are returned to a holding tank for approximately twelve hours
to allow the pressure differential to equalize, giving a stabilised granule.

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Final Forming
– In this final stage the pre-expanded stabilized beads
are reheated with steam in a mould.
– The final expansion takes place and the beads
coalesce to give a shaped moulding.
– This can also be used to form large blocks which
can be sectioned to the required shape as panels,
boards, cylinders etc.
– In this final form the EPS is made up of 98% air.

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Insert Moulding : Inserts can either be incorporated at the
time of the moulding process, or be inserted as a post
moulding operation
Typical Materials Used
Most thermoplastics can be processed with the use of

Inserts. Acrylonitrile
Butadiene Styrene, Nylons(Polyamides), Polycarbonate,
Polypropylene, Polystyrene
Typical Products Produced Metal Screw in Type, Plastic
pre-moulded, RF Shielding, Bearing Inserts, Decorative
Labels
Moulding Expanded Polystyrene (EPS) : Expanded

polystyrene (EPS) is used for the production of a number
of applications. However its major application is as a
protective packaging for consumer electronic products and
white goods.
Typical Materials Used
Polystyrene
Typical Products Produced : Packaging, Tea cups

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Blown Film
• Blown film can be used either in tube form (e.g. for plastic
bags and sacks) or the tube can be slit to form a sheet.
• Typical applications are industry packaging and consumer
packaging
• Polyethylenes - HDPE, LDPE and LLDPE( linear LDPE) are
the most common resins in use, but a wide variety of other
materials can be used as blends with these resins or as single
layers in a multi-layer film structure. these include pp, pa,
evoh (ethylene vinyl alcohol)
• Plastic melt is extruded through an annular slit die, usually
vertically, to form a thin walled tube
• Air is introduced via a hole in the centre of the die to blow up
the tube like a balloon
• Mounted on top of the die, a high-speed air ring blows onto
the hot film to cool it
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Blown Film
• The tube of film then continues upwards, continually
cooling, until it passes through nip rolls where the tube is
flattened to create what is known as a ' lay-flat' tube of film
• This lay-flat or collapsed tube is then taken back down the
extrusion ' tower' via more rollers.
• The lay-flat film is then either kept as such or the edges of
the lay-flat are slit off to produce two flat film sheets and
wound up onto reels
• If kept as lay-flat, the tube of film is made into bags by
sealing across the width of film and cutting or perforating to
make each bag. This is done either in line with the blown
film process or at a later stage.

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Vacuum Forming : Vacuum formed products are all
around us and play a major part in our daily lives.
Virtually all thermoplastics can be supplied as sheet
and vacuum formed.
Typical Materials Used Acrylonitrile Butadiene
Styrene, Polyester Copolymer, Polystyrene,
Polycarbonate, Polypropylene, Polyethylene (sheet
and foamed sheet), Polyvinyl Chloride, Acrylic
Typical Products Produced Baths & Shower Trays,
Boat Hulls, Vehicle Door Liners, Sandwich Boxes,
Machinery Guards, Refrigerator Liners, Parts of
vehicle cabs
Blown Film : The process involves extrusion of a

plastic through a circular die, followed by "bubble-
like" expansion.
Typical Materials Used Polyethylenes (HDPE,
LDPE and LLDPE)
Typical Products Produced : Plastic bags and sacks

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Structural Foam Moulding

• Structural Foam is a term commonly used to describe
thermoplastic injection moulded components which have a
cellular core.
• The outer surface is denser than the inner layers
• The core of the moulding is of a honeycomb nature and less
dense than the outer surface
• The combination results in a moulding of a high stiffness ratio
compared with non-structural foam (compact) mouldings.
The Low Pressure Process
 To achieve consistent quality mouldings, it is recommended to use
dedicated special purpose injection moulding machines.
 The machines introduce a gas into the melted plastic which when injected
into the closed mould tool subsequently foams the plastic material of the
component being produced.
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Structural Foam Moulding Process

Conventional Moulding Machines
• Another widely used method is the use of standard injection
moulding machines with added "blowing agents" incorporated
into the material.
• Using dry chemical blowing agents mixed in with the granules
of plastic, the plastic is melted in the barrel of the machine.
• A measured charge is injected into the mould tool.
• The heat of the melted plastic causes the blowing agent to react,
which forms a gas, which in turn foams the plastic.
• Almost all thermoplastic materials can be foamed and wall
sections at 5 -- 15 mm, are thicker than compact (normal)
injection mouldings.
• The nature of the process leaves a rough streaky surface finish
on the surface of mouldings
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Structural Foam : Is used to describe thermoplastic
injection moulding components made by the injection
moulding process which have a cellular core.
Typical Materials Used Acrylonitrile-Butadiene-
Styrene, Polystyrene, Polycarbonate, Polypropylene,
Polyvinyl chloride
Typical Products Produced Business Machine
Housings, Business Machine Chassis Components,
Material Handling Containers
Rotational Moulding : It differs from all other
processing methods in that the heating, melting,
shaping, and cooling stages all occur after the
polymer is placed in the mould, and no external
pressure is applied during forming.
Typical Materials Used Polyethylene
(Low Density) LDPE, LLDPE; Polypropylene PP;
Ethylene Vinyl Acetate EVA; Polyvinyl Chloride,
Typical Products Produced : Manhole inspection
chambers, Slides and climbing frames, Childrens
playhouses, Canoes and kayaks, Rainwater tanks,
Diesel fuel tanks,  M.S Ramaiah School of Advanced Studies - Bangalore 34
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Thermoset forming processes
Casting
Compression molding (fixtures,
( electrical devices, Vulcanization
low production
small parts) Transfer molding ( rubber products)
parts
Reaction Injection molding (high production)
(auto parts, business
Injection molding machine parts)
Rotational casting
(high volume production) (casting)
Sintering
(stock shapes,
Small parts)
Foam processing
(insulation, bedding, auto parts)

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Thermoset Processes
• Thermosetting materials start as liquids/syrups,
often called "resins", as powders or partially cured
products ("preforms") which need heat for the
shaping phase.
• The shaping is accompanied by a chemical reaction,
which means that the material does not soften on
reheating.
• The reaction may be exothermic (giving heat out),
in which case cooling is required.

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Compression Molding
•Most common technique for producing moldings from
thermosetting plastics and elastomers.
•Products range in size from small plastic electrical moldings and
rubber seals weighing a few gms, up to vehicle body panels and
tires.
•A matched pair of metal dies is used to shape a polymer under the
action of heat and pressure.

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Foam molding
Various techniques produce –
dense at the skin and high
porosity in the core. (fig)
Process involves – charging the
metal mold with foam, that
expand during reaction.
The expansion of the foaming
resin fills the mold cavity.
Similar process used for large
parts with exception that the
Cross section of an foam polymer resin is injected into
molded part the cavity rather than being
charged.
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Reaction Injection Molding

Polymer reactants under high
Pressure - mixing chamber
Flow into the reaction mold –
under atm pressure
Chemicals expand to fill the mold
Foaming action of the reactants
produces the pressure for
replication of molds and the
reaction heat speeds the polymer
cure.

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Transfer Molding
Molding material – open cylinder, heated and transferred

under pressure into a part cavity.
Modification of compression molding.

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Casting
Hollow shapes from molten

polymer.
Liquid material is poured
into an mold without
significant pressure followed
by solidification and curing.

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Vulcanization Process making rubber

rubbery – application of
heat and pressure to cause
polymer branching.
Tape of partially reacted
rubber wrapped around a
roll of desired thickness.
Tape rubber is shrink
wrapped with plastic film
and placed in autoclave.
Steam heated autoclave
produces heat and rubber –
consolidation of tape to
solid rubber coating on roll.
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Special Purpose Materials

SMC or Sheet Moulding Compound
Definition:
• A fiber glass reinforced thermosetting compound in sheet form, usually rolled
into coils interleaved with plastic film to prevent auto adhesion.
• Made by dispensing mixed resin, fillers, maturation agent, catalyst and mold
release agent onto two moving sheets of polyethylene film.
• The lower one also contains chopped glass roving or glass mat. SMC can be
molded into complex shapes with little scrap.
Advantages
• Processing of SMC by compression or injection moulding enables the
production of bodywork or structural automotive components, and electrical or
electronic machine housings in large industrial volumes.
• The process also penetrates sectors such as sanitary ware (baths) and urban
furniture (stadium and cinema seating) etc.

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Composition of SMC
SMC or Sheet Moulding Compound

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SMC Manufacturing Process

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Sheet Molding Compound (SMC)

• Design
http://www.smc-alliance.com/welcome/welcome.html
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SMC Components

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DMC or Dough Moulding Compound
Also called as BMC or Bulk Moulding Compound
Definition:
Molding compound consisting of thermosetting plastic resins mixed with stranded
reinforcement, fillers, and other additives. This viscous compound can be used for
compression or injection molding.
DMC is a combination of chopped glass strands with resin in the form of a bulk
prepreg.
BMC is suitable for either compression or injection moulding. Smaller components
are usually made by the injection moulding process.
•Larger components being compression (or transfer) moulded.
Injection moulding of BMC is used to produce complex components such as
1. Electrical equipment
2. Car components (headlamps are an important application for BMC)
3. Housings for electrical appliances
4. Tools, in large industrial volumes.
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Composition of BMC
BMC or Dough Moulding

Compound
BMC Manufacturing Machine

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Advantages of BMC
Technical Advantages:
•Very rigid and stiffer than thermoplastics
•Ability to integrate all the housing functions
•No mechanical rework needed
•No paint: BMC can be mass coloured
•Reduced cycle time compared to aluminium
•Longer life of BMC tools
•Dimensional stability and higher precision compared to aluminium
•Noise reduction : BMC has a dampening effect on vibrations
Economic Advantages:
•50 % total cost savings in comparison to cast aluminium

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BMC Components

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SMC Moulding (Compression Moulding):
Thermosetting materials in sheet form are known as
Sheet Moulding Compound (SMC). These sheets
consist of liquid thermosetting resins mixed with
glass fibers, catalysts, fillers and pigments .
The sheets are placed between heated moulds in a
hydraulic press and compression pressure is applied
DMC Moulding (Transfer Moulding): Dough or

Bulk Moulding Compounds (DMC or BMC)
In transfer moulding, the liquid thermoset/
unvulcanized rubber is placed in a chamber (called a
pot), usually at the top of the mould, and the assembly
is placed in a press. The press applies pressure to a
piston-like plug in the open end of the pot, clamping
the halves of the mould together and forcing the
material to flow through one or more spruces into the
heated mould.

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DMC Moulding (Compression Moulding)
: The operator pre-weighs a charge of
material and places it into the open mould.
The heated mould and pressure flows the
material into the cavity. The heat cures the
resin, which hardens the moulded part.
Typical Products Produced Electrical
switch and fuse boxes. Domestic electrical
equipment microwave containers and
tableware. Business machine housings. Gas
and electricity meter housing. Dish aerials.
Transfer Moulding Compression Moulding

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Ultrasonic Welding
• Ultrasonic Welding uses high
frequency energy which is
transmitted through the parts to melt
and bond thermoplastic materials.
• This technique is fast, efficient, non-
contaminating and requires no
consumables.
• In addition to welding, ultrasonic
processes can be used to insert,
stake, stud weld, degate, and spot
weld thermoplastics as well as seal,
slit, and laminate thermoplastic
films and fabrics.

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Linear Vibration Welding

• Linear vibration welding uses the
frictional heat generated at the
joint interface of the two parts to
be welded to melt the plastic.
• The heat energy is achieved by
moving one part relative to its
mating piece under pressure
through a given displacement or
amplitude.
• Once the desired amount of melt
has been achieved, the vibration
is stopped, and the parts are held
together under force for a short
period of time, allowing the weld
area to solidify.

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Orbital Welding

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Orbital Welding
• Orbital vibration welding is a friction welding
process
• In orbital vibration welding, the upper section is
vibrated using constant velocity orbital motion –
circular motion in all directions.
• This motion generates heat, which raises the plastic
to its melting point.
• Once melting occurs, the motion is stopped,
allowing the plastic to solidify into a permanent
bond.
• Low clamping pressure results in minimum part
distortion.
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Spin Welding

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Spin Welding
• Spin welding joins thermoplastic parts with a
circular joint area by bringing the part interfaces
together, under pressure, with a circular, spinning
motion.
• One part is held stationary in a fixture, while the
other is rotated against it under pressure.
• At least one section must be circular.
• The frictional heat that is generated causes the part
interfaces to melt and fuse together, creating a
strong, hermetic seal.
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Summary
• Polymers can be converted to components through a
number of manufacturing processes
• The manufacturing process to be selected is based
on material used, production volumes, part
geometry and accuracy
• Injection moulding is the most widely used
manufacturing process for mass production of
polymer components, and produces parts of
complex geometry, accuracy and good surface
finish at a high production rate

Session-12-Polymer Manufacturing

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PEMP- EMM2512

 M.S Ramaiah School of Advanced Studies - Bangalore 1

• By the end of the session the delegate

 M.S Ramaiah School of Advanced Studies - Bangalore 2

Unit Operations in Polymer Processing

Unit Operations in Polymer Processing

 M.S Ramaiah School of Advanced Studies - Bangalore 4

 M.S Ramaiah School of Advanced Studies - Bangalore 5

Zones in Injection Moulding Machine

Heaters for melting

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Injection Moulding Process

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Typical Materials Used : Acrylonitrile-

Injection Moulding (Gas Assisted ) :

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 M.S Ramaiah School of Advanced Studies - Bangalore 10

The forcing of a plastic or molten material through a shaped die

 M.S Ramaiah School of Advanced Studies - Bangalore 11

To form hollow shapes - do not require a homogeneous thickness

Extrusion Blow Moulding

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Injection Blow Moulding Process

Injection Blow Moulding Process

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Injection Stretch Blow Moulding : Injection stretch

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Thermoplastic and thermosets.

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Expanded Polystyrene Moulding

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Expanded Polystyrene Moulding

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Expanded Polystyrene Moulding

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Most thermoplastics can be processed with the use of

Moulding Expanded Polystyrene (EPS) : Expanded

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Blown Film : The process involves extrusion of a

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Structural Foam Moulding

Structural Foam Moulding Process

Thermoset forming processes

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Reaction Injection Molding

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Molding material – open cylinder, heated and transferred

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Hollow shapes from molten

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Vulcanization Process making rubber