Compression Moulding

Compression Moulding is a technique principally for thermoset plastic moulding in which the moulding
compound (generally preheated) is placed in the heated open mould cavity, mould is closed under
pressure, causing the material to flow and completely fill the cavity, pressure being held until the
thermoset material has cured.

In this process a measured quantity of a plastic material is shaped or formed by heat and pressure. A
known weight or volume of the moulding powder is kept in an open mould cavity. The mould consists of
two halves, a male and a female part, and is normally preheated. Mould halves are attached to the
upper or lower platens of a press. These mould halves are called the core or plunger and the cavity. Heat
is applied either directly to the mould or indirectly through the platens. A systematic diagram of
Compression Moulding is given in the following Figure.

The moulding compound, generally in powder form, is placed in the mould cavity after which the mould
is closed. Heat and pressure is applied causing the plastic material to soften, flow and fill the cavity
completely. Depending on the characteristics of the plastic material and the design of the mould, the
temperature ranges from 140°C to 250°C & pressure range from 2000 to 10,000 psi. The mould remains
heated and closed until the plastic material cures and sets.

A moulding pressure of 2000 psi on the total projected area of the part is generally recommended. To
this must be added approximately 800 psi for every inch of the vertical height of the moulded part, to
arrive at total moulding pressure required.

After the material has cured sufficiently, the mould is opened and the piece is ejected by knockout pins.
The cure time depends on the size and thickness of the part. This may vary from 20 seconds to 10
minutes. The cure time cannot be predicted accurately, but must be determined by experience or by
trial.
Materials for compression moulding:

Thermosetting resins: Phenol formaldehyde, Urea formaldehyde, Melamine formaldehyde, Unsaturated

Polyester, Epoxy Resin.

Process operations:

1. Pelleting (an optional stage) 2. Preheating (also optional)

3. The moulding stage 4. Finishing operations

Moulding sequence:

(i) Mould open, Cavity cleaned,

(ii) Pellet loaded, Mould closing,

(iii) Mould closed - Curing stage,

(iv) Mould open, Moulding ejected.

1. Pelleting:

Pelleting permits accurate measurement of the charge to the mould reduces contamination and
facilitates preheating. It does not, however, always fit in very well with more automated compression
systems.

2. Preheating:

Preheating is useful in that it reduces expensive moulding time, allows rapid heating of large pellets or
masses of powder. Helps to remove moisture and other volatiles prior to moulding and because it
advances the cure has been claimed to reduce moulding shrinkage.
3. The Moulding Stage:

The powder material (specified) is placed inside the heated mould cavity and mould is closed,
predefined pressure is continuously applied on to the moulding.

Since the material will start to cure as soon as it comes into contact with the heated mould. It is
important that flow and shaping be completed before the gel point is reached (i.e. the material shows
first signs of being cross linked). The optimum cures (i.e. cross-linking) for one property is not necessarily
the best cure for another. It is therefore necessary to establish what properties are important in the
finished moulding and use cure times and temperatures that give a good compromise to the various
requirements, including that of cost. It is particularly important that flow and cross-linking process are
controlled and are in the correct sequence. While improvements in the operation can often be made by
such refinement as breathing (venting) they will be no value if the basic process is not correct.

4. Finishing Operation:

The part finishing is done depending upon the product comes out after curing. Sometimes it is observed
that additional material is coming out from the moulding as a flash which can be removed after curing.
To make more attractive some other finishing operations can be performed on to the finished product.

Compression Moulding Cycles:

Hydraulic Type Compression Moulding Press:
Advantages:

• Lowest cost molds

• Little "throw away" material provides advantage on expensive compounds

• Often better for large parts

• Lower labor costs

• Minimum amount of wasted material & Improved material efficiency

• Internal stress and warping are minimized.

• Dimensional accuracy & stability is excellent.

• Shrinkage is minimized and closely reproducible.

• Thick sections and large parts are practically possible.

 • Lower molding pressures allow molding of large parts on presses of lower tonnage

Limitations:

• Offers least product consistency

• Not suitable for fragile mold features, or small holds

• Uneven parting lines present a mold design problem

• High impact composites make flash control & removal difficult.

• The depth of the molded holds is limited to 2 or 3 times their diameter

• Shot weight must be tightly controlled

• Dimension across the parting line may be difficult to hold but good accuracy may be
obtained through tight process control.

Applications:

Radio & appliance knobs, Ash trays & Electrical parts. (Electrical switch and fuse boxes),
Domestic electrical equipment microwave containers and tableware. Business machine
housings. Gas and electricity meter housing, Dish aerials etc.