Methods of polymer fabrication

Extrusion of polymers
Injection Molding
Blow Molding
Thermoforming
Compression Molding
Casting
Extrusion of polymers
method used mainly for thermoplastics

is a continuous process as long as raw pellets are supplied

is a process of manufacturing mostly long products of constant

cross-section;
i.e.. rods, sheets, pipes, films, wire insulation coating
… extrusion

pelletized material is successively compacted, melted and

formed into a continuous charge of viscous fluid
temperature of the material is controlled by thermocouples

forcing soften polymer through a die with an opening

the product going out of the die is cooled by blown air or in

water bath
extruder
Injection Molding
most widely used technique for thermoplastics
highly productive method, profitable in mass production of
large number of identical parts

polymer in form of pellets is fed into machine and is pushed

forward into a heating chamber then the molten plastic is
forced through a nozzle into the enclosed mold cavity
pressure is maintained until solidification and then the mold
opens and the part is removed
Blow Molding
is a process in which a heated hollow thermoplastic tube
(parison) is inflated into a closed mold
disposable containers, recyclable bottles, automotive fuel
tanks, tubs are produced
involves manufacture of parison by extrusion, injection or
stretching
parison in a semi molten state is placed in a two piece mold
having the desired shape

parison is inflated by air blown, taking a shape conforming that

of the mold cavity

parison is then cut on the top, mold cools down, its halves
open, and the final part is removed
Thermoforming
is a process of shaping flat thermoplastic sheet
softening the sheet by heat, followed by forming it in the mold
cavity
Thermosets can not be formed by the thermoforming because
of their cross linked structure
widely used in the food packaging industry; manufacturing of
Thermoforming methods
three thermoforming methods, differing in the forming stage:

1. Vacuum Thermoforming; shaping a preheated thermoplastic

sheet by means of vacuum produced in the mold cavity

2. Pressure Thermoforming;... by means of air pressure.

3. Mechanical Thermoforming;... by direct mechanical force

Thermoforming by vacuum and mechanical force
Compression Molding
used mostly for molding thermoset resins

pre-weighed amount of a polymer mixed with additives is

placed into the lower half of the mold
polymer is preheated prior to placement into heated mold
cavity ,half of the mold moves down, pressing on the polymer
charge and forcing it to fill the mold cavity

suitable for molding large flat or moderately curved parts; side

panels for automotive, electric housings etc.
Casting
both thermosets and thermoplastics may be cast.

molten polymer is poured into a mold and allowed to solidify

for thermoplastics solidification occurs upon cooling

while thermoset’s hardening is a consequence of
polymerization reaction
REFERENCES
François Carderelli, Materials Handbook: A Concise Desktop
Reference,2nded.,Springer
Donald Hudgin, Plastics Technology Handbook, 4th ed., Taylor & Francis
Group
J. A.Brydson, Plastics Materials, 7thed., Heinemann
William D. Callister ,Materials Science and Engineering,7th ed., Wiley
http://www.substech.com
http://www.azom.com
http://en.wikipedia.org