University of the East - Manila

Mechanical Engineering Department

Materials Science & Engineering for ME

Plastic Manufacturing Process
PLATE 5

ROYO, ANGELICA JULIANNE A.

20200116569 – ME1
ENGR.DIOSDADO DOCTOR
PROFESSOR
 TABLE OF CONTENTS

I. DEFINITION OF TERMS………………………………………………...………………….3

II. INTRODUCTION…………………………………………………………………..………..4

III. MANUFACTURING PROCESS……………………………………………………………6

A. FLOWCHART……………………………………………………..………………...6

B. DISCUSSION OF PROCESS…………………………..…………….…...…………9

C. RAW MATERIALS……………………………………..………….....………....….10

D. EQUIPMENT OR MACHINERIES…………………………………………...……11

IV. DEFECTS…………………………………………….……………………………………..11

V. REFERENCES………………………...…………………………………………..………...12

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Definition of Terms

Acrylonitrile Butadiene Styrene - This plastic is an opaque thermoplastic and amorphous

polymer greatly used in the plastic manufacturing industry.

Extrusion - the action of thrusting or forcing something out.

Hard Hat - a rigid protective helmet, as worn by factory and building workers.

Perforation - a hole or break in the containing walls or membranes of an organ or structure of

the body

Plastic – It is a synthetic material made from a variety of organic polymers such as polyethylene,
PVC, nylon, and others that can be shaped while soft and then set into a rigid or slightly elastic
form:

Thermoforming - the process of heating a thermoplastic material and shaping it in a mold.

Thermosetting Polymer or Thermoset - It is a polymer that is formed by permanently

hardening (“curing”) a soft solid or viscous liquid prepolymer (resin).

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Introduction

Plastic has become such an integral part of our culture, serving as a common material to
produce end-use parts and products ranging from consumer goods to medical devices. Accepting
a plastic item without thinking about the material and disposing of it within minutes is second
nature. Every year, humans generate 380 million tons of plastic. And half of that is single-use;
items we buy and then discard within minutes.

A wide range of plastics manufacturing processes have been developed to accommodate

a wide range of applications, part geometries, and plastic types. Any product designer or
engineer working on development must be familiar with the manufacturing options available
today as well as the new developments that indicate how parts will be manufactured in the
future.

Most plastics in use today are made from hydrocarbons, which are organic molecules
composed entirely of carbon and hydrogen. These hydrocarbons are derived from biological
materials found within the Earth's crust and are known as fossil fuels. Fossil fuels are made from
the petrified, buried remains of long-dead plants and animals.

The most common type of plastic is thermoplastic. The ability to go through numerous
melt and solidification cycles without significant degradation distinguishes them from
thermosets. Thermoplastics are typically delivered in the form of small pellets or sheets that are
heated and formed into the desired shape using a variety of manufacturing processes. Because no
chemical bonding occurs, the process is completely reversible, making recycling or melting and
reusing thermoplastics possible.

• Acrylic (PMMA);
• Acrylonitrile butadiene styrene (ABS);
• Polyamide (PA);
• Polylactic acid (PLA);
• Polycarbonate (PC)
• Polyether ether ketone (PEEK);
• Polyethylene (PE);
• Polypropylene (PP); and

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 • Polyvinyl chloride (PVC).

In contrast to thermoplastics, thermosetting plastics (also known as thermosets) cure to a

permanent solid state. Polymers in thermosetting materials crosslink during a curing process
induced by heat, light, or appropriate radiation. This curing process results in the formation of an
irreversible chemical bond. Thermosetting plastics decompose rather than melt when heated and
will not reform when cooled. It is not possible to recycle thermosets or return the material to its
base ingredients.

Common types of thermoplastic materials:

• Cyanate ester;
• Epoxy;
• Polyester;
• Polyurethane;
• Silicone; and
• Vulcanized rubber.

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Manufacturing Process

Flowchart

Raw Material & Mixing of Color

Vacuum System to Machine

Melting Machine

Molding of Molten Plastic Molting of Molten Plastic Molding of Molten Plastic

Molding Molding Head Band

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Suction Cup to Transfer Plastic Key

Transferring

Injection Hole

Securing Key in a loop Strap

Cutting of Injection

Assembly

Checking of Sharp Edge

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 Safety Certified Logo Printing Impact Test

Packaging Transport Packaging Hammer Impact Test

Transportation

Product: Hard Hat

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Discussion of Terms

Plastic Extrusion

When extruding plastic, a hopper is used to feed plastic pellets or powder into the
extruder. Polymer is heated inside a barrel at a controlled temperature, and the molten plastic is
forced through a metal die using a screw before being cooled and pulled into the final shape. The
length of the product can be adjusted by cutting or trimming it. This is a popular method for
producing plastic goods. Pipes, ventilation, door and window frames, and seals are just some of
the many products that can be efficiently mass-produced through the plastic extrusion process.

Injected Molding

The plastic polymer is fed into a heated barrel and screw via a hopper. The screw heats
the plastic to its melting point, and then injects the liquid polymer into a split mould tool that is
heated to the appropriate temperature to form the desired shape. Many different parts, from the
smallest screws to the largest vehicle bumpers and trash cans, can be produced quickly using
injection molding, making it ideal for mass production. To create the desired shape, molten
plastic is pressed into a die, as opposed to being extruded.

Vacuum Casting

Technique for fabricating low-volume runs of functional plastic prototypes or small parts.
Using a vacuum to draw the liquid raw material (such as Polyurethane resins, cast nylon, waxes)
into the mold, vacuum casting is a highly adaptable technology for elastomers. When air
entrapment is a concern, when there are intricate details or recessed surfaces, or when the
material is reinforced with fiber or wire, this method is employed (e.g. glass-filled Nylon). After
releasing the vacuum, the raw material is poured into the silicone mold. After removing the mold
from the curing chamber, the casting is cured in an oven. after which the casting was released by
removing it from the mold. Mold is recyclable.

Thermoforming

During this procedure, a plastic sheet that has already been extruded is heated to a pliable
temperature, stretched over a mold, and finally trimmed to the desired shape. Rapid production
of thousands of parts is made possible by the machines. Disposable cups, containers, lids, trays,

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blisters, and other items for the food, medical, and retail industries are just a few examples.
Plastic vacuum forming is like a stripped-down version of thermoforming.

Compression Molding

Thermoset polymers are where you'll most often find it in use (irreversibly becomes rigid
when heated). After being heated, the raw material goes into a mold that has been left open.
Closing the mold's top and applying pressure distributes the material evenly throughout the
mold's interior. The material is kept under intense heat and pressure until it has hardened. The
formed product is easily removable after curing. Plastic injection molding is commonly used to
produce car body panels like hoods, fenders, and spoilers, along with a wide variety of other
components. It is also commonly employed in the fabrication of honeycomb and polymer foam
sandwich structures.

Finishing and Testing

When everything is said and done, solid parts get their final color coating, which may
include painting or spray painting. Smooth finishing is performed manually or by automatic
machines. Following this, quality assurance procedures are carried out, and defective goods are
thrown away. The finished items are boxed up and sent out to stores.

Raw Materials

The plastic known as ABS is an abbreviation for acrylonitrile butadiene styrene, which is
its full name. This plastic is an amorphous thermoplastic that sees widespread application in the
industry that manufactures plastic. The fact that ABS plastics are thermoplastic and adapt to the
temperature of their surroundings makes them extremely useful.

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Equipment or Machineries

A vacuum is a device that uses a compressed air pump to create an internal environment
suitable for entrapping dust and dirt particles for removal. Floors, carpets, furniture, and any
other surfaces prone to dust accumulation are typical targets for this tool's dusting and cleaning
capabilities. A dust bag or specialized tank inside the device can store the dirt that has been
collected from the intended surfaces.

Molding Machine

To facilitate the creation of a sand mold, a molding machine is used. This machine is
made up of several interconnected parts that transmit and modify various forces and motions.
Also known as machine molding, this technique is used in industrial settings for high volume
output.

Defects

1. Cracking and perforation;

2. Deformity of the brim or shell; and
3. Indication of exposure to heat, chemicals, ultraviolet light and radiation (exhibited by
chalking or flaking) combined with a loss of surface gloss.

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References

alifah. (2022, November 23). Plastics Manufacturing Process: Step-by-Step Guide.

Intrepid Sourcing & Services. https://intrepidsourcing.com/plastics-
manufacturing-process-step-by-step-
guide/#:~:text=Plastics%20Manufacturing%20Process%201%20Extraction%20
of%20Raw%20Materials
Guide to Manufacturing Processes for Plastics. (2018). Formlabs.
https://formlabs.com/blog/guide-to-manufacturing-processes-for-plastics/
What are the manufacturing processes for plastics? (n.d.). D W Plastics.
https://www.dwplastics.co.uk/manufacturing-processes-for-plastics/
What are the manufacturing processes for plastics? (n.d.). D W Plastics.
https://www.dwplastics.co.uk/manufacturing-processes-for-plastics/
Machine Moulding - Types, Definition, Operation, Advantages [Images]. (2021,
November 14). Marinerspoint Pro. https://marinerspointpro.com/machine-
moulding/#What_is_Machine_Moulding

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