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![Page 1: Plastics part production methods Machining Laminating Thermoforming Polyurethane methods Rotational moulding Blow moulding Expandable Foam (Styrox) Injection.](https://reader035.fdocuments.net/reader035/viewer/2022081420/5697c0091a28abf838cc72a3/html5/thumbnails/1.jpg)
Plastics part production methodsMachiningLaminating Thermoforming Polyurethane methods Rotational mouldingBlow mouldingExpandable Foam (Styrox) Injection mouldingExtrusion
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Injection mouldingBlow mouldingRotational moundingVacuum formingResin Casting Laminating Cutting Clueing Bending
Quantity
Production method / quantity
1 10 100 1000 10 000 100 000
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Machining plastics
• No moulds needed• Methods
– Sawing – Lathe – Milling– Punching– Water and laser cutting
• Semi-finished products – Rods – Sheets – Profiles – Tubes and pipes– Films
• Wood and metal machines– Special blade– Small series– CAD
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MuoviteknologiaTeppo Vienamo
Composite plastics
• Fibers• Glass,
• Carbon
• Aramid
• Natural fibers
• Matrix• Polyester
• epoxy http://w1.siemens.com
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MuoviteknologiaTeppo Vienamo
Hand lay up
Resin+fibre, 1+1>2•Composite material properties:+ Easy to produce complex shapes+ Large one piece parts+ In mould coating+ Tailored strength properties (directional)+ Chemical, corrosion resistance+ Strength/weight ratio+ Difficult to copy (piracy)+/-Heat/electrical resistance+/-Manufacturing+/-Reparability+/-Price
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MuoviteknologiaTeppo Vienamo
Thermoforming, Vacuum forming
• Thermoplastics• Small series in large objects• Large quantities in thin packages • Material thinners unequally • Usually natural mold, E.G. wood,
epoxy or aluminium• ABS, PS and PE-HD, thickness 1-8
mm • Often a lot vaste from a sheet
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MuoviteknologiaTeppo Vienamo
Use
• Refrigerator inside• Terhi-boats • Vehicle • Small series device• Packaging• Briefcase• Trays • Ski box, trailer cover
http://www.terhi.fi/static_2003/fin/boat_bigfun.php
http://www.muoviura.fi/index2.htm
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MuoviteknologiaTeppo Vienamo
Vacuum forming method
• Sheet is heated
• Blow to a bubble
• Lifting mould
• Vacuum
• Cooling off
• Cutting
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MuoviteknologiaTeppo Vienamo
Polyurethane methods
• Hard integral urethane
• Flexible integral urethane
• Cold cast cushion polyurethane
• RIM reaction injection moulding
• RRIM reinforced reaction injection moulding
• Urethane elastomer
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MuoviteknologiaTeppo Vienamo
Rotational moulding
• Big hollow objects• Unexpensive moulds, • Medium size series• Equal thickness • Production cycle 5-25 min• Thermoplastics PE-HD,
PE-MD, PE-LD, (PA, PC)
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MuoviteknologiaTeppo Vienamo
Rotationalmoulding method• Rotational moulding
machine rotates mould around two axis
• Closed thin walled metallic mould
• Plastic powder in to cold mould
• Rotating mould to oven
• Plastic melts and gets sinter
• Cooling and opening the mould
http://www.reinhardtindia.com/rotational.html
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MuoviteknologiaTeppo Vienamo
Typical products
• Tanks and liquid containers• Composter • Planting plot • Rapids canoe• Fuel tanks• Balls • Toys
http://www.hometone.com/wp-content/uploads/2012/07/kon01_uExBR_1822.jpg
http://www.taloon.com/kuvat/k/biolan/biolan_pikakompostori_220_eco_vihrea.jpg
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MuoviteknologiaTeppo Vienamo
Mass production
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MuoviteknologiaTeppo Vienamo
Injection moulding
• Series size over 10 000
• Structures and functions integrated
• Accurate products
• Ready after moulding, no after processing
• All thermoplastics and some others
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MuoviteknologiaTeppo Vienamo
Typical use
• Most common method
• electronics, gadget chases
• dishes
• Sport equipment
• Car parts
• E.G.
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MuoviteknologiaTeppo Vienamo
Injection moulding method
1. Plastics granulates are melted by heating and friction while screw withdraws and collects melt to the front
2. Screw injects melt in to the mould
3. Part gets cooled
4. Mould opens and part is ejected
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MuoviteknologiaTeppo Vienamo
Design guides
• Even wall thickness
• Avoid planar surfaces
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MuoviteknologiaTeppo Vienamo
Design guidelines
• Draft
• Sink mark
• Weld line
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MuoviteknologiaTeppo Vienamo
Mould shrinkage
• Even 3 %
• Bending
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MuoviteknologiaTeppo Vienamo
Co-injection moulding
www.bath.ac.uk/~en9ng/ page6.htm.
subscriber.scoot.co.uk/ hymid/4.htm.
• Surface and core different material– Recycled – Soft surface
• Joint in mould– Technically superior– Finished product– Quicker cooling– Aesthetics – Expensive mould
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MuoviteknologiaTeppo Vienamo
Gas assisted injection moulding • Thick parts• No sinks• Cheaper mould • Light weight part• Rigid
- material distributes some randomly
- rare method
www.designinsite.dk/ gifs/pb2000.gif
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MuoviteknologiaTeppo Vienamo
Extrusion blow moulding
• Large series • Hollow barrel like
parts, bottles canisters air channels
• Tool cases
• PE
www.blowmoulding.it/GRANDI/ Prodotto02.jpg
www.portmanproducts.co.uk/ case.gif
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MuoviteknologiaTeppo Vienamo
Method
• extruded hose
• Closed between mold halves
• Pressurised air
• cooling
• opening
• cutting BlowMoulding.JPG1200 x 1659 kuvapistettä - 137 ktwww.mech.uwa.edu.au/.../Scans-Polymers/ BlowMoulding.JPG
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MuoviteknologiaTeppo Vienamo
Injection blow moulding
• Injection moulded preform, heated
• Blown open in a mould
• Accurate mouth
• Water bottles
• PET, PC
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MuoviteknologiaTeppo Vienamo
Design guidelines
• Planar surfaces bends outwards
• Corners stretch thin
• Inserts possible
• Double cavity bottles
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MuoviteknologiaTeppo Vienamo
Extrusion
• Profiles, tubes, sheets, film
• Calibrating line for accurate shapes
• Thermoplastics, (some thermosets) PE-HD, PP, PVC PMMA
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MuoviteknologiaTeppo Vienamo
method
• Plastics granulate plastisides by pressure , friction and heat
• Screw pushes melt to nozzle
• Calibrating / cooling
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MuoviteknologiaTeppo Vienamo
Typical products
• Films• Pipes• Seals• Building profiles• Cover profiles• Sheets• Window frames
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MuoviteknologiaTeppo Vienamo
Special methods
• Film production• Corrugated tube• dual-extrusion• Big cylinders by
adding small profile to the side of it self like a thread
http://plastics.turkavkaz.ru/processes/extrusion/blown-film-extrusion/
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MuoviteknologiaTeppo Vienamo
EPS Encapsulated Polystyrene (PP, PA)
• Pre swelled grains to mould
• Selling by steam
• Cooling with water
• Opening
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MuoviteknologiaTeppo Vienamo
Typical products
• Bicycle helmets
• Shock absorption for packaging
• Thermal insulation, cold boxes
• Laminate core