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Molding: Molding or Moulding Is The Process of
Molding: Molding or Moulding Is The Process of
A mold or mould is a hollowed-out block that is filled with a liquid or pliable material such
as plastic, glass, metal, or ceramic raw material.[2] The liquid hardens or sets inside the mold,
adopting its shape. A mold is the counterpart to a cast. The very common bi-valve molding
process uses two molds, one for each half of the object. Piece-molding uses a number of
different molds, each creating a section of a complicated object. This is generally only used
for larger and more valuable objects.
The manufacturer who makes the molds is called the moldmaker. A release agent is typically
used to make removal of the hardened/set substance from the mold easier. Typical uses for
molded plastics include molded furniture, molded household goods, molded cases, and
structural materials.
Blow molding
Powder metallurgy plus sintering
Compression molding
Extrusion molding
Injection molding
Laminating
o Reaction injection molding
Matrix molding
Rotational molding (or Rotomolding)
Spin casting
Transfer molding
Thermoforming
o Vacuum forming, a simplified version of thermoforming
(Wikipedia)
What is Molding?
“Molding is the process of manufacturing by shaping liquid or pliable raw material using a
rigid frame called a mold or matrix. This itself may have been made using a pattern or model
of the final object.”
“A mold or mould is a hollowed-out block that is filled with a liquid or pliable material like
plastic, glass, metal, or ceramic raw materials. The liquid hardens or sets inside the mold,
adopting its shape. A mold is the counterpart to a cast. The very common bi-valve molding
process uses two molds, one for each half of the object. Piece-molding uses a number of
different molds, each creating a section of a complicated object. This is generally only used
for larger and more valuable objects.”
“The manufacturer who makes the molds is called the moldmaker. A release agent is
typically used to make removal of the hardened/set substance from the mold easier. Typical
uses for molded plastics include molded furniture, molded household goods, molded cases,
and structural materials.”
Blow Molding
Compression Molding
Structural Foam Molding
Injection Molding
Reaction Molding
Transfer Molding
http://kentmold.com/molding/
Casting
Casting is a basic molding process as it requires the least amount of complex technology.
Plastic is simply heated so it turns into a fluid, and then transferred into a mold. It is left to
cool and the mold is removed. This process can be used for intricate shapes and performed
under a low pressure. However, it is a common process used for making plastic sheeting,
starting from 0.5 inches thick and greater.
Injection Molding
Injection molding is used for creating high-quality three-dimensional objects, that can be
commercially reproduced. The molding process begins by melting plastic in a hopper. Then
the plastic is injected into a tightly closed, chilled mold. The plastic quickly takes the shape
of the surrounding mold. Once it has completely set, the mold is opened and the plastic object
is released. Yogurt pots, butter tubs, toys and bottle caps are made using this process.
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Blow Molding
Blow molding is a process used for making piping and milk bottles. Plastic is heated until
molten. Then it is injected into a cold mold. The mold has a tube set within it, which has a
particular shape when inflated. So, while the plastic is molten, air is blown into the tube and
the plastic is formed around the tubing. It is then left to cool and removed from the mold.
Compression Molding
Rotational Molding
Toys, shipping drums, storage tanks and items of consumer furniture are made using
rotational molding. Each object is made by coating a mold from the inside. A mold is held in
place between two mechanical arms. Then, the arms rotate the mold constantly at the same
level, while molten plastic is placed inside. As it turns, the plastic coats the inside of the mold
to create a new hollow, plastic object.
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invention :
Micro-molding Innovations in the Medical Field
New Materials
Because many devices have to be removed from the body at some point following their
implantation, the medical field stands to gain from new micro-molded bio-absorbable
components. Bio-absorbable devices are absorbed by the body after they have served their
purpose, eliminating the need for a secondary procedure to remove the product. Such devices
may offer a way around the side-effects of using metal devices, such as screws, which
sometimes lead to a negative reaction in the body.
Bio-absorbable materials tend to be quite expensive, but micro-molding uses very little
material. Parts can be created at such a small size that literally a million can be made per 2.5
lbs of material, but some specialty resins can cost as much as 22, 000 dollars per pound.
Despite the expense, since micro-molded parts use a small amount of material they are
sometimes less expensive to produce than alternative options.
Although bio-absorbable parts aren’t new, the recent improvements in the way they are made
and their overall effectiveness is making them more attractive. There are, however, problems
with absorbable materials when it comes to their ability to resist dissolving when exposed to
high-temperatures.
New Techniques
Earlier forms of micro-molded devices lacked the thin-wall technology that now marks
current products. Additionally, new standards call for tighter tolerances—no matter how
small the part, tolerances approximately range between 0.001 and 0.0001 inches. The need
for tight tolerances has led to the improvement in micro-molding machines. Today, many
micro-molding machines even remove, package, and visually inspect the parts they create.
CNC machines and silicon-water technology are two processes that have been tailored to
create precise cavities for the production of micro-molded part. Additionally, studying the
techniques used by watchmakers may prove helpful, as both watchmakers and micro-molders
work with extremely small and precisely engineered parts.
Finishing such a small part poses a bit of a problem since it can’t be done by hand. It is also
extremely important that finishing be done properly, as it is potentially dangerous to insert a
jagged or unfinished piece into the body. Stereolithography is currently being explored as a
possible finishing option.
In an attempt to improve the speed at which the parts can be produced and overall part
precision, hot and cold runner systems are being adapted to suit micro-molding. As parts are
continually micro-molded in smaller and smaller sizes, the processes by which they are
manufactured may need to be re-examined and improved upon.
http://www.thomasnet.com/articles/plastics-rubber/micro-mold-innovation
http://www.aimplastics.com/services/manufacturing/