PLASTICS

INTRODUCTION TO PLASTIC
• Plastic is a material consisting of any of a wide range of synthetic or semi-synthetic
organic compounds that are malleable and therefore can be molded into solid objects.
Plasticity is the general property of all materials that involves permanent deformation
without breaking. Polymers’ name is derived from their flexible and plastic properties.

• Plastics are typically organic polymers of high molecular mass, but they often contain
other substances. They are usually synthetic and most commonly derived from
petrochemicals. However, today’s focus on the environment has led to a growing number
of plastics to be derived from renewable materials such as polylactic acid from corn or
cellulosic from cotton linters.

• Plastics have been adopted in a significant, and ever-expanding, range of products thanks
to their relatively low cost, ease of manufacture, versatility, and imperviousness to water.
They can be found in products as simple as paperclips or as complex as planes.
• A large source of diverse plastic material is available across a
widespread manufacturing spectrum.
• One of the most recent and exciting manufacturing domains is in 3D Printing.
As new applications for 3D Printing are discovered almost daily, a diverse
array of plastic objects have already been produced using the 3D Printing
process.
• These objects can be found in prototyping labs, toys, mechanical gearboxes,
medical prosthetics, and many more.
• Plastics are generally classified by the chemical structure of the
polymer's backbone and side chains; some important groups in these
classifications include:
• Acrylics
• Polyesters
• Silicones
• Polyurethanes
• Halogenated plastics
EARLY AND MODERN PLASTICS
Plastic materials were first used at around 2000BC.
Plastics can occur naturally in trees or even milk; amber is
an example (a resin from trees and insects). Amber was
used by early Egyptians to make jewellery and is still used
for this purpose today.

Today, numerous different plastics are

available. Some are still made from natural
materials but most modern plastics are
manufactured from chemicals obtained from
crude oil. Plastics manufacturers convert
chemicals into plastics.
OIL - THE RAW MATERIAL FOR PLASTICS
Pump
Pipeline
We obtain crude oil from
Oil well under ground, either on
land or at sea.

Layers of After it has been pumped, it

rock is heated in a fractioning
tower and broken down
into chemicals.
Gas
The chemicals consist of
Oil nitrogen, carbon, chlorine,
sulfur and water.
CATEGORIES OF PLASTICS
• Natural plastics - these are naturally occurring materials that can be said to be plastics
because they can be shaped and molded by heat.
• An example of this is amber, which is a form of fossilized pine tree resin and is often used in
jewelry manufacture.
• Semi synthetic plastics - these are made from naturally occurring materials that have
been modified or changed but mixing other materials with them.
• An example of this is cellulose acetate, which is a reaction of cellulose fiber and acetic acid and is
used to make cinema film.
• Synthetic plastics - these are materials that are derived from breaking down, or
’cracking’ carbon based materials, usually crude oil, coal or gas, so that their molecular
structure changes. This is generally done in petrochemical refineries under heat and
pressure, and is the first of the manufacturing processes that is required to produce most
of our present day, commonly occurring plastics.
• Synthetic and semi synthetic plastics can be further divided into two other categories.
These two categories are defined by the ways in which different plastics react when
heated.
COMPOSITION
• Most plastics contain organic polymers.
• The vast majority of these polymers are based on chains of carbon
atoms alone or with oxygen, sulfur, or nitrogen as well.
• The backbone is that part of the chain on the main "path" linking a
large number of repeat units together.
• To customize the properties of a plastic, different molecular groups
"hang" from the backbone (usually they are "hung" as part of the
monomers before the monomers are linked together to form the
polymer chain).
BIODEGRADABILITY
• Biodegradable plastics break down (degrade) upon exposure to
sunlight (e.g., ultra-violet radiation), water or dampness, bacteria,
enzymes, wind abrasion, and in some instances, rodent, pest, or
insect attack are also included as forms
of biodegradation or environmental degradation.
• Some modes of degradation require that the plastic be exposed at the
surface, whereas other modes will only be effective if certain
conditions exist in landfill or composting systems.
• Starch powder has been mixed with plastic as a filler to allow it to
degrade more easily, but it still does not lead to complete breakdown
of the plastic.
• Some researchers have actually genetically engineered bacteria that
synthesize a completely biodegradable plastic, but this material, such
as Biopol, is expensive at present.
• Companies have made biodegradable additives to enhance the
biodegradation of plastics.
BIOPLASTIC
• Most plastics are produced from petrochemicals. Motivated by the
finiteness of petrochemical reserves and threat of global warming,
bioplastics are being developed.
• Bioplastics are made substantially from renewable plant materials
such as cellulose and starch.
CRYSTALLINE VS AMORPHOUS
• Some plastics are partially crystalline and partially amorphous in
molecular structure, giving them both a melting point (the
temperature at which the attractive intermolecular forces are
overcome) and one or more glass transitions (temperatures above
which the extent of localized molecular flexibility is substantially
increased).
• The so-called semi-crystalline plastics include polyethylene,
polypropylene, poly (vinyl chloride), polyamides (nylons), polyesters
and some polyurethanes.
• Many plastics are completely amorphous, such as polystyrene and its
copolymers, poly (methyl methacrylate), and all thermosets.
WHY DESIGN WITH PLASTICS?
• Light weight, high weight to strength • Relatively low cost compared to
ratio, particularly when reinforced metals and composites

Density Cost
WHY DESIGN WITH PLASTICS?
• Corrosion resistance
• Low electrical and thermal conductivity, insulator
• Easily formed into complex shapes, can be formed, casted and joined.
• Wide choice of appearance, colors and transparencies
DISADVANTAGES OF USING PLASTICS
• Low strength
o
• Low useful temperature range (up to 600 F)
• Less dimensional stability over period of time (creep effect)
• Aging effect, hardens and become brittle over time
• Sensitive to environment, moisture and chemicals
• Poor machinability
POLYMERS
• The earliest synthetic polymer was developed in 1906, called Bakelite.

• The development of modern plastics started in 1920s using raw material

extracted from coal and petroleum products (Ethylene). Ethylene is called a
building block.
• Polymers are long-chain molecules and are formed by polymerization
process, linking and cross linking a particular building block (monomer, a unit
cell).
• The term polymer means many units repeated many times in a chainlike
structure.
• Most monomers are organic materials, atoms are joined in covalent bonds
(electron-sharing) with other atoms such as oxygen, nitrogen, hydrogen,
sulfur, chlorine,….
 POLYMER’S STRUCTURES
Bonding – monomers are linked together by covalent bonds, forming a polymer chain (primary bonds).
The polymer chains are held together by secondary bonds. The strength of polymers comes in part from
the length of polymer chains. The longer the chain, the stronger the polymer. More energy is needed to
overcome the secondary bonds.
Linear polymers Branched polymers

A sequential structure resulting in thermoplastics Side branch chains are attached to the main chain
like nylon, acrylic, polyethylene. A linear polymer which interferes with the relative movement of the
may contain some branched and cross-linked molecular chains. This results in an increase in strength,
chains resulting in change in properties. deformation resistance and stress cracking resistance.
Lower density than linear chain polymers.
Cross-linked polymers
Three dimensional structure, adjacent chains are linked by covalent
bonds. Polymers with cross-linked chains are called thermosetting
plastics (thermosets), epoxy and Silicones.

Cross-linking is responsible for providing hardness, strength, brittleness and

better dimensional stability.

Network polymers
A three dimensional network of three or more covalent
bonds. Thermoplastic polymers that have been already
formed could be cross-linked to obtain higher strength.
Polymers are exposed to high-energy radiation.
ADDITIVES IN PLASTICS
• Additives are added to polymers in order to obtain or improve certain
properties such as strength, stiffness, color, resistance to weather and
flammability.
• Plasticizers are added to obtain flexibility and softness, most common use
of plasticizers are in PVC.
• Ultraviolet radiation (sunlight) and oxygen cause polymers to become stiff
and brittle, they weaken and break the primary bonds. A typical treatment
is to add carbon black (soot) to the polymer, it absorbs radiation.
Antioxidants are also added to protect against degradation.
• Fillers such as fine saw dust, silica flour, calcium carbide are added to
reduce the cost and to increase harness, strength, toughness, dimensional
stability,…..
• Colorants are added to obtain a variety of colors. Colorants are either
organic (dye) or inorganic (pigments). Pigments provide greater
resistance to temperature and sunlight.
• Flame retardants such as chlorine, phosphorus and bromine, are
added to reduce polymer flammability. Teflon does not burn and
nylon and vinyl chloride are self-extinguishing.
• Lubricants such as mineral oil and waxes are added to reduce friction.
CLASSIFICATION OF POLYMERS
• Thermoplastics
• As the temperature is raised above the melting point, the secondary bonds
weaken, making it easier to form the plastic into any desired shape. When
polymer is cooled, it returns to its original strength and hardness. The process
is reversible. Polymers that show this behavior are known as
thermoplastics.
• Thermosetting Plastics (thermosets)
• Thermosetting plastics are cured into permanent shape. Cannot be re-melted
to the flowable state that existed before curing, continued heating for a long
time leads to degradation or decomposition. This curing (cross-linked)
reaction is irreversible. Thermosets generally have better mechanical,
thermal and chemical properties. They also have better electrical resistance
and dimensional stability than do thermoplastics.
 The word ‘plastic’
What does
means the
‘easily
word ‘plastic’
shaped or
Thermoplastic plastics: mean?
moulded’.
Formed by heat

Soften when heated

Made of long
polymer chains with
few cross links

Can be reheated
and reshaped
Mostly recyclable
Thermosetting plastics:

Initially set by heat

Consist of polymer Cannot be reshaped

chains with strong once set
bonds between
each chain

Strong and durable Common in powder

or resin forms
THERMOPLASTIC PLASTICS

The majority of common plastics are thermoplastics.

Thermoplastics can be heated and reshaped because
of the ways in which the molecules are joined together.
Heat
This can be repeated many times (as long as no
damage is caused by overheating).
Harden Soften

Cool
THERMOSETTING PLASTICS
Thermosetting plastics are those which are set with heat and have little elasticity.
Once set, they cannot be reheated and reformed.
Burn
They are heated and moulded during
manufacture.
Once cooled, they will not soften again when Heat
heated. This breaks the potentially unending cycle
that thermoplastic plastics are capable of.
Harden Soften
If heated too much, they burn.

Cool
 USES OF PLASTICS (THERMOPLASTICS)

Here are some

common products
made from
thermoplastics. Polystyrene
Can you say which High density
Polypropylene polythene Low density polythene
type of
thermoplastic
each one is made
of? ABS
Acrylic

What other uses do these thermoplastics have?

 USES OF PLASTICS (THERMOSETS)

Epoxy
Thermosets resin Phenol
have different
formaldehyde
qualities to
thermoplastics. Melamine
formaldehyde Urea
formaldehyde

GRP
APPLICATION OF THERMOSETTING PLASTICS
• Thermoset plastics offer enhanced high-performance combination of thermal stability,
chemical resistance, and structural integrity.
• Thermoset components are used extensively in a wide range of industries – and are used
for applications in the automotive, appliance, electrical, lighting, and energy markets due
to excellent chemical and thermal stability along with superior strength, hardness, and
moldability.
• Thermoset plastic composites are capable of meeting the specifications of a wide range
of production materials at a very low cost.
• Their use allows for an assortment of small and large parts to be fabricated with high
production volume while maintaining their repeatability consistently from batch to
batch.
• Thermosets provide an alternative process when complex and geometric shapes cannot
be achieved through metal fabrication or the use of thermoplastics but can be
manufactured in a mold.
• Thermoset plastics maintain their stability in all environments and temperatures.
ADVANTAGES OF THERMOSETS
• The use of thermoset plastics has a number of advantages. Unlike
thermoplastics, they retain their strength and shape even when
heated. This makes thermosetting plastics well-suited to the
production of permanent components and large, solid shapes.
Additionally, these components have excellent strength attributes
(although they are brittle), and will not lose significant strength when
exposed to higher operating temperatures.
• Thermosets plastics have gained in popularity among manufacturers,
who have switched to their use as a lower cost replacement for metal
components.
• The benefits that thermoset plastics can offer over their metal
counterparts include:
• Available molded-in tolerances
• Choice of color and surface finishes
• High strength-to-weight ratio and performance
• Outstanding dielectric strength
• Low thermal conductivity and microwave transparency
• Resistance to corrosion effects and water
• Lower tooling/set-up costs
• Reduced production costs over fabrication using metals
DISADVANTAGES OF THERMOSETS
• There are certain disadvantages to the use of thermosets whereas the
material properties are not as developed as those of thermoplastics.
• The low initial viscosity of materials results in flash and the need for
secondary operations. Also, low tensile strength and ductility tend to
result in parts that require designs with thick walls. The compounds
used in thermosets are reactive systems, which can impact the useful
shelf life. Batch processes may exhibit greater variation and less
consistency from lot-to-lot. High levels of some filler in the materials
may result in excessive tool wear. The product quality is dependent
upon the degree of crosslinking established during the molding cycle.
TYPE OF THERMOSETS & THERMOSET
MATERIALS LIST
• Thermosetting polymers are built from • RTM Thermosetting Plastics (Fiberglass-
various types of material that serve key reinforced):
roles and applications in the plastics • Polyester
fabrication industry. • Vinyl Ester
• The two thermoset molding compound • Polyimides
processes are Reaction Injection Molding • Other Types of Thermosets and Thermoset
(RIM) and Resin Transfer Molding (RTM). Resins:
• Specific types of thermoset materials that • Epoxy (e.g., carbon fiber epoxy resin)
are in use within the plastics fabrication • Phenolics
industry include the following: • Bismaleimide (BMI)
• Fluoropolymers
• RIM Thermosetting Plastics: • Polytetrafluoroethylene (PTFE)
• pDCPD (polydicyclopentadiene) • Polyvinylidene fluoride (PVDF)
• Polyurethanes • Melamine
• Polyureas • Silicone
• Structural Foams • Urea Formaldehyde
APPLICATIONS OF THERMOPLASTICS
• In polluted, acidic, environments such as may be found in modern cities, steel piping
systems are often vulnerable to rust or corrosion and therefore need special provisions
for corrosion protection. The cost associated with protecting steel piping systems that
are exposed to these harsh environments can be expensive. Thermoplastics are
considered to be a favorable substitute to minimize these costs. Certain properties of
thermoplastics that make them a suitable substitute material are:
• Their ability to withstand corrosive materials and corrosive environments.
• Being able to carry materials of extreme temperatures (hot or cold).
• Their capacity to handle virtually any type of fluid transport application.
• Common materials used to produce these pipes are PVC or CPVC. Additional materials
include polypropylene, PVDF, ABS, nylon, and polyethylene. Polyethylene gas tanks are
used to transport natural gas for use in residential and commercial applications.
• Other common applications for thermoplastics include high-pressure polyethylene to
encapsulate rigid objects like electrical equipment. Low-pressure polyethylene is very
elastic and ideal for insulating electrical cables. Polyamide is most commonly associated
with the production of ropes and belts.
ADVANTAGES AND DISADVANTAGES OF
THERMOPLASTICS
• The primary advantage of thermoplastics is their wide range of applications.
Thermoplastics are high strength, lightweight materials and have relatively low
processing costs. Additionally, thermoplastic components are relatively easy to
manufacture with high volume and precision.
• The primary disadvantage of using thermoplastics instead of materials such as
metal is their relatively low melting point. Certain types of low-quality
thermoplastics can melt when they're exposed to the sun for extended periods.
Furthermore, thermoplastics can have poor resistance to organic solvents,
hydrocarbons, and highly polar solvents.
• Thermoplastics are susceptible to creep, which occurs when the material
stretches and weakens under exposure to long-term stress loads. The
susceptibility to creep is further exacerbated by the lower melting temperature of
the material. Other types of thermoplastics, such as composites, can fracture
instead of becoming deformed under high-stress conditions.
TYPES OF THERMOPLASTIC MATERIALS
• Types of thermoplastics commonly employed for manufacturing include polyethylene
(PE), polyvinyl chloride (PVC) and polystyrene (PS), which often is used for packaging.
Other groups of thermoplastics are acrylics, fluoropolymers, polyesters, polyimides, and
nylons. All of these types can be melted down repeatedly and re-shaped into different
forms. For example, a foam cup is a thermoplastic material man be re-melted and
fabricated into a dish.
• Some of the most common thermoplastic materials in use include:
• Polycarbonate
• Acetal Copolymer Polyoxymethylene
• Acetal Homopolymer Polyoxymethylene
• Acrylic
• Nylon
• Polyethylene
• Polypropylene
• Polystyrene
• Polyvinyl chloride (PVC)
• Teflon
GENERIC PLASTIC MATERIALS
• Acrylonitrile Butadiene Styrene (ABS) is a terpolymer produced by polymerizing styrene
and acrylonitrile in the presence of polybutadiene. Most applications can withstand
temperatures of between -20–80°C (-4–176°F). Common applications include electronic
equipment cases such as computer monitors, printers, and keyboards as well as drainage
pipes.
• Polyamide (PA) or nylon occur both naturally, for example with wool and silk, and
synthetically as nylons, aramids, and sodium poly(aspartate). Synthetic polyamides are
commonly implemented in the textile, automotive, carpet, and sportswear industries for
their durable and strong properties. The transportation manufacturing industry is
estimated to consume 35% of worldwide polyamide (PA) globally. Some key applications
include fibers, toothbrush bristles, tubing, fishing line, and low-strength machine parts in
engines or gun frames.
• Polycarbonates (PC) belong to the thermoplastic carbonate-containing polymer group.
Their strong, tough properties and the transparency of some grades makes them suitable
for engineering. Additionally, their flexible properties make them easy to work, mold,
and thermoform, therefore polycarbonates (PC) can be found in many applications such
as compact discs, eyeglasses, riot shields, security windows, traffic lights, and lenses.
• Polyester (PES) can occur naturally, for example in the cutin of plant cuticles, and
synthetically through step-growth polymerization such as polybutyrate. Natural
polyesters, and a few synthetic ones are biodegradable, but most synthetic
polyesters are not. Polyesters can be found extensively in the clothing and textile
industries.
• Polyethylene (PE) is the most common plastic with an annual global production
of approximately 80-million tons. It is mainly used the packaging sector for plastic
bags, plastic films, geomembranes, and containers (including bottles).
• High-density polyethylene (HDPE), also known as polyethylene high-density
(PEHD) is a thermoplastic derived from petroleum with a high strength-to-density
ratio. It is mainly used in detergent bottles, milk jugs, molded plastic cases, plastic
bottles, corrosion-resistant piping, geomembranes, and plastic lumber. When
used for pipes, it is sometimes called alkathene or polythene.
• Low-density polyethylene (LDPE) is a thermoplastic made from the monomer ethylene.
First produced in 1933 by Imperial Chemical Industries (ICI), its manufacture employs the
same method today. Also, its implementation remains widespread in outdoor furniture,
siding, floor tiles, shower curtains, and clamshell packaging despite competition from
more modern polymers.
• Polyethylene terephthalate (PET), commonly abbreviated PET or PETE is the most
common thermoplastic polymer resin of the polyester family. It is mainly used in fibers
for clothing, containers for liquids and foods, thermoforming for manufacturing, and in
combination with glass fiber for engineering resins. Brand names include: Dacron,
Terylene, or Lavsan.
• Polypropylene (PP), also known as polypropene, is a rugged and corrosion-resistant
addition polymer that belongs to the thermoplastic polymer group. After polyethylene, it
is the second-most widely produced synthetic plastic. It is used in a broad spectrum of
applications such as packaging, labeling, textiles, stationary, plastic parts, reusable
containers, laboratory equipment, loudspeakers, automotive components, and polymer
banknotes.
• Polystyrene (PS) is a synthetic aromatic polymer made from the monomer styrene and
can be solid or foamed. General-purpose polystyrene is clear, hard, and relatively brittle
and is an inexpensive resin per-unit weight. It is naturally transparent but can be colored.
As one of the most widely used plastics, being produced in the millions of tons per year,
it is commonly used for foam peanuts for packaging, food containers, plastic tableware,
disposable cups, plates, cutlery, compact-disc (CD) and cassette boxes.
• High-impact polystyrene (HIPS) is a graft copolymer produced by mixing polystyrene
with the stretchier polybutadiene rubber during polymerization, which results in high-
impact polystyrene (HIPS), often called “high-impact plastic” in advertisements. It
commonly injection molded to produce toys, refrigerator liners, food packaging, and
vending cups. One brand name is Bextrene.
• Polyurethane (PUR and PU) is a polymer composed of organic units joined by carbamate
(urethane) links. Although most polyurethanes are thermosetting polymers that do not
melt when heated, thermoplastic polyurethanes are also available. Common applications
include: cushioning foams, thermal insulation foams, surface coatings and printing
rollers. It is the most commonly used plastic in automobiles.
• Polyvinyl chloride (PVC) is also known as PVC, poly vinyl or vinyl and is the
world’s third-most widely produced synthetic plastic polymer after polyethylene
and polypropylene. PVC is available in either a rigid (RPVC) or flexible form.
Common applications for RPVC include plumbing pipes, gutters, doors, window
frames, and bank or membership cards. Common applications for flexible PVC
include shower curtains, flooring, imitation leather, signage, phonograph records,
inflatable products, and the various applications where it replaces rubber.
SERIES OF STEPS IN PLASTIC
MANUFACTURING PROCESS
RAW MATERIAL EXTRACTION
• The first step in the production of plastic objects is extracting the raw
material that is derived from natural gas or refined crude oil. The
drilling is done by heavy machinery to take out raw material from the
underground.
• The collected raw material is sent through the pipes for the refinery
process. To make pellets of pure plastic, heating of oil and gas is
performed. After that refined polyethylene chain are integrated which
is called polymerization to get god clarified plastic.
SETTING & PREPARATION OF MOLD &
PRINTERS
• In the next phase, molds are prepared according to the desired design
of plastic products. The settings of molds and printers tools are the
most significant step, as they help to produce objects according to
specification. They are adjusted manually or sometimes by robotics.
The heated & melted plastic is then injected into these molds to give
shape. It is important to control the temperature of plastic heating
during the melting process.
MAIN TECHNICAL PROCESSING
• This major practical step contains the mass production of parts by using specialized
machines. The master processing includes multiple activities depending on what type of
methodology is implemented for assembling of plastic;
• Blow Molding: A heated plastic tube is blown to make hollow plastic parts. It is popular for making
plastic bottles, toys, and automotive components.
• CNC Machining: CNC stands for Computer numerical control. The CNC is a subtractive process that
involves grinding, cutting, boring, and drilling of solid plastic blocks, rods, and bars.
• Vacuum Forming: Variety of plastic shapes ii formed by vacuum forming method. In vacuum
forming plastic is heated, stretched over the mold surface, and then vacuum force is applied.
• Polymer Casting: The resin is liquefied by heat. The melted rubber is filled closed in the mold and
curd at room temperature. After cooling cured plastic is pulled out from the mold.
• Injection Molding: Molten thermoplastic is poured into the mold and pressed by shot chamber
through a screw.
• 3D Printing: It creates a three-dimensional physical model of objects with the help of a
computerized printer.
• Extrusion: Extrusion means applying pressure or force on the die to form a shape
• Rotational Molding: Rotational plastic crates hollow plastic products by rotating on two axes.
COOLING & REMOVAL OF PLASTIC
• Once the plastic parts are formed they are de-molded after cooling
down. The solid part is ejected and sent for final processing.
FINISHING & TESTING OF PARTS
• In the end, solid parts are painted, sprayed, and the final color coating
is done. Smooth finishing is performed manually or by automatic
machines. After that, quality control procedures are executed and
damaged products are discarded.
THE PLASTIC FORMING &
MANUFACTURING PROCESS:
TOP 7 TECHNIQUES
PLASTIC INJECTION MOLDING
• Plastic injection molding accounts for about 80% of the durable plastic items we
find every day. Injection molding uses a mold or die made from aluminum or
steel. The mold consists of a core side and a cavity side that is placed into a plastic
injection molding machine. This machine heats the raw plastic resin pellets until
they’re molten, injects them into the empty cavity of the mold under great
pressure, and then opens to eject the finished part.
• The advantage of PIM is that millions of identical parts can be made quickly, with
excellent surface finish and at low cost. Molds however can be expensive and
complex, depending on the part geometry. Careful engineering design of the
mold is required to prevent defects and optimize part quality and processing
speed.
ROTATIONAL (ROTO) MOLDING
• Rotational molding also uses a core and cavity mold tool, but the manufacturing
process is quite different.
• Plastic powder is poured into the cavity of the mold, and the mold placed in an
oven. While being heated, the mold is slowly rotated on two axes. Gravity is used
to stick the plastic to the tool walls and build up the correct thickness.
• Then, the mold is removed from the oven and slowly cooled to prevent warpage.
Full cooling can take several minutes, after which the tool is opened and the part
removed for the next cycle.
• Rotational molding is ideal for making large, hollow or concave shapes, often for
outdoor use like canoes and tubs. The finished parts are stress-free and have no
seams so they’re strong, and the tools are relatively simple and inexpensive to
make. The downside is that tools don’t last more than a few thousand cycles
before they need to be replaced, and the part finish quality is average at best so
it’s not suited for precision forming.
EXTRUSION BLOW MOLDING
• This is the most common way to make thin-walled, inexpensive
containers like disposable drinking cups or bottles. It’s fast and the
tools are easy to make, but the parts cannot be very complex or made
with high precision.
• Molten plastic in the form of a large droplet, called a parison, is
placed into a two-piece clamshell mold. After the mold closes, the
parison is inflated like a balloon until it fills the empty cavity. Because
the walls of the mold are water- cooled, the plastic quickly solidifies
and the bottle can be ejected.
INJECTION BLOW MOLDING
• During injection blow molding, gas pressure is used to force molten
resin into a mold cavity. The process is easily controlled and
repeatable, and is commonly used for transparent plastic drinking
bottles. It makes for excellent surface quality but it’s not ideal for thin
walls.
• PET (polyethelene terephthalate) or PEEK (polyether-ether-ketone)
are the typical choices resin choices for drinking bottles, due to their
clarity and durability, and because they are rated as safe for
consumables. They are also easily recycled.
REACTION INJECTION MOLDING (RIM)
• RIM is most often used in the automotive industry because it produces
lightweight parts that have a rigid skin. This skin is easily painted to make
body panels, dashboards and other car parts. However, thermoforming
plastics won’t work in this process. Instead this process requires
thermosetting plastic.
• Thermosetting plastics undergo an irreversible chemical reaction inside the
mold. This usually causes them to expand like a foam, filling a mold cavity.
When the chemical reaction is done the plastic sets into its final form.
• Tooling costs for prototypes are relatively low, while production tooling is
moderately expensive. The main cost is in the material, bearing in mind
that the resulting part must always be finished, usually with a urethane-
based gel coat or by painting, so the process is more labor intensive which
increases the piece price.
VACUUM CASTING
• Vacuum casting is a great choice for making a small number of high-
quality rapid prototypes without a big investment in tools or material.
• A master model of any rigid solid (often this is a 3D printed master
pattern) is placed into a sealed box that’s then filled with a flexible
urethane or silicone. When the master is removed, a cavity is formed
inside the mold that can now be filled with plastic resin to form a
copy of the original. Vacuum pressure is used to pull air out of the
mold so that it fills completely with no air bubbles.
• In this process, the surface finish quality and detail are excellent and
pourable resins can imitate many engineering grades of plastic. But
the molds are not durable and will degrade after 20 or so copies.
THERMOFORMING
• This is a type of vacuum forming, where thin or thick gauge plastic
sheet is placed over a die, heated to a temperature that allows the
material to become pliable, then is stretched over the surface of the
die while vacuum pressure pulls the sheet down and into its final
shape.
• This process can also be done with simple dies and very basic
equipment. It’s often employed with samples and prototypes of thin-
walled, hollow-bodied parts. In industry, it’s used for plastic cups,
lids, boxes and plastic clamshell packaging, as well as for auto body
parts in thicker gauge material. Only thermoforming plastics are
suitable for this process.
COMPRESSION MOLDING
• The raw material is pre-heated and placed inside the open cavity of a
die. A cap or plug is used to close the die and apply heat and
pressure, causing the plastic to cure. This process is great for rubber
keypad switches, gaskets, O-rings and other soft, pliable thin-walled
parts.
• It’s relatively inexpensive and wastes little material, although
controlling the consistency of the finished piece can be difficult and
much care needs to be taken in the preparation of the initial mold
design.