Types of Molding Processes

Molding is primarily used during the manufacturing process of plastic. Plastic is a

synthetic materials, and to form it into the desired shape different molding
processes are used. Each process requires the manipulation of molten plastic, and
then leaving it to set. Thermoplastics can then be melted down and reformed if
necessary, however thermoset plastics cannot be reheated.

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.

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
The most labor-intensive type of molding process is compression molding.
Therefore, it is only used for large-scale production purposes, and not for mass
production. For example, boat hulls and car tires are made using this method.
Molten plastic is poured into a mold. Then a second mold is pressed into it. This
squeezes the plastic into the desired shape before being left to cool and removed
from the mold.
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.

Components Required for Moulding:

1. Moulding Sand (Green Sand)
2. Moulding Boxes
3. Pattern
4. Moulding Tools
1. Moulding Sand:
Green sand is an aggregate of sand, bentonite clay, pulverized coal and
water. Its principal use is in making molds for metal casting. The largest
portion of the aggregate is always sand, which can be either silica or olivine.
Green sand (and other casting sands) is usually housed in what casters refer
to as flasks which are nothing other than boxes without a bottom or lid. The
box is split into two halves which are stacked together in use. The halves are
referred to as the top (cope) and bottom (drag) flask respectively. Green
sand is not green in color, but “green” in the sense that it is used in a wet
state (akin to green wood). of wood or metal. Wood is cheaper and boxes
can be made quickly. Wood wears out quickly. It is destroyed by contact
with hot metal. A metal box is steel, cast iron and aluminum alloys are used
in mass production. Moulding boxes are used for making sand moulds.
2. Moulding Box:
It is also called moulding flask. It is frame or box of wood or metal. Wood is
cheaper and boxes can be made quickly. Wood wears out quickly. It is
destroyed by contact with hot metal. A metal box is steel, cast iron and
aluminum alloys are used in mass production. Moulding boxes are used for
making sand moulds.
3. Pattern:
In casting, a pattern is a replica of the object to be cast, used to prepare the
cavity into which molten material will be poured during the casting process.
Patterns used in sand casting may be made of wood, metal, plastics or other
materials The making of patterns, called pattern making (sometimes styled
 pattern-making or pattern making), is a skilled trade that is related to the
trades of tool and die making and mold making, but also often incorporates
elements of fine woodworking.

4. Moulding Tools:

a) Shovel:
It is one of the foundry tools which have a broad metal blade with a long
wooden handle. It is used to carry moulding sand from the sand pit to the
moulding box and is also used for mixing and tempering (adding sufficient
water) the sand.

b) Riddle:
It is a metal sieve used for removing foreign materials such as stones, nails etc.,
from the moulding sand.

c) Rammer:
It is used for packing or ramming the moulding sand in the moulding box.

d) Trowels:
It is used for smoothening the surfaces of mould and also to repair the damaged
portion of mould.

e) Slick:
It is used for repairing and finishing surfaces and to round corners of the mould.

f) Lifter:
It is used to remove the loose sand from the mould. It is also used to finish the
bottom and sides of the mould.

g) Strike off bar:

It is used to remove excessive sand from the mould after tempering.

h) Sprue pin:
It is used to make sprue hole to pour the molten metal in the mould.

i) Vent rod:
It is used for making vent holes in the sand mould so that the molten gases released
during casting process, can easily escape from mould.
J) Bellows:
It is used to blow off loose sand particles from the mould and pattern.

k) Gate cutter:
It is used for cutting gates and runners in the mould.

Question:
1. What is moulding?
2. what is casting
3. Describe different types of moulding processes
4. What are the tools required for moulding?