Compression molding

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Compression molding - simplified diagram of the process

Compression molded rubber boots before the flashes are removed.

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Compression molding is a method of molding in which the molding material,

generally preheated, is first placed in an open, heated mold cavity. The mold is
closed with a top force or plug member, pressure is applied to force the material
into contact with all mold areas, while heat and pressure are maintained until the
molding material has cured; this process is known as compression molding
method and in case of rubber it is also known as 'Vulcanisation'. [1] The process
employs thermosetting resins in a partially cured stage, either in the form of
granules, putty-like masses, or preforms.

Compression molding is a high-volume, high-pressure method suitable for

molding complex, high-strength fiberglass reinforcements. Advanced composite
thermoplastics can also be compression molded with unidirectional tapes, woven
fabrics, randomly oriented fiber mat or chopped strand. The advantage of
compression molding is its ability to mold large, fairly intricate parts. Also, it is
one of the lowest cost molding methods compared with other methods such as
transfer molding and injection molding; moreover it wastes relatively little
material, giving it an advantage when working with expensive compounds.

However, compression molding often provides poor product consistency and

difficulty in controlling flashing, and it is not suitable for some types of parts.
Fewer knit lines are produced and a smaller amount of fiber-length degradation is
noticeable when compared to injection molding. Compression-molding is also
suitable for ultra-large basic shape production in sizes beyond the capacity of
extrusion techniques. Materials that are typically manufactured through
compression molding include: Polyester fiberglass resin systems (SMC/BMC),
Torlon, Vespel, Poly(p-phenylene sulfide) (PPS), and many grades of PEEK.[2]

Compression molding is commonly utilized by product development engineers

seeking cost effective rubber and silicone parts. Manufacturers of low volume
compression molded components include PrintForm, 3D, STYS, and Aero MFG.
Compression molding was first developed to manufacture composite parts for
metal replacement applications, compression molding is typically used to make
larger flat or moderately curved parts. This method of molding is greatly used in
manufacturing automotive parts such as hoods, fenders, scoops, spoilers, as
well as smaller more intricate parts. The material to be molded is positioned in
the mold cavity and the heated platens are closed by a hydraulic ram. Bulk
molding compound (BMC) or sheet molding compound (SMC), are conformed to
the mold form by the applied pressure and heated until the curing reaction
occurs. SMC feed material usually is cut to conform to the surface area of the
mold. The mold is then cooled and the part removed.

Materials may be loaded into the mold either in the form of pellets or sheet, or the
mold may be loaded from a plasticating extruder. Materials are heated above their
melting points, formed and cooled. The more evenly the feed material is
distributed over the mold surface, the less flow orientation occurs during the
compression stage.[3]

Compression molding is also widely used to produce sandwich structures that

incorporate a core material such as a honeycomb or polymer foam. [4]

Thermoplastic matrices are commonplace in mass production industries. One

significant example are automotive applications where the leading technologies
are long fibre reinforced thermoplastics (LFT) and glass fiber mat reinforced
thermoplastics (GMT).

In compression molding there are six important considerations that an engineer

should bear in mind[citation needed]:

● Determining the proper amount of material.

● Determining the minimum amount of energy required to heat the
material.
● Determining the minimum time required to heat the material.
● Determining the appropriate heating technique.
● Predicting the required force, to ensure that shot attains the proper
shape.
● Designing the mold for rapid cooling after the material has been
compressed into the mold.

Process definition[edit]

Compression molding is a forming process in which a plastic material is placed

directly into a heated metal mold then is softened by the heat and therefore
forced to conform to the shape of the mold, as the mold closes. Once molding is
completed excess Flash may be removed. Typically, compression molding
machines open along a vertical axis.

Process characteristics[edit]

The use of thermoset plastic compounds characterizes this molding process

from many of the other molding processes. These thermosets can be in either
preform or granule shapes. Unlike some of the other processes we find that the
materials are usually preheated and measured before molding. This helps to
reduce excess flash. Inserts, usually metallic, can also be molded with the plastic.
As a side note, remember not to allow any undercuts on the shape, it will make
ejection especially difficult. Thermoplastic matrices with an inherent indefinite
shelf-life and shorter cycle molding times are widely used and examples are
shown in Ref 3.

Process schematic[edit]

Compression molding is one of the oldest manufacturing techniques for rubber

molding[citation needed]. The process parameters include molding time, temperature,
and pressure. Usually, a 300-400 ton clamp pressure is used. The typical mold is
shaped like a clam shell with the bottom being the mold cavity. The molding
press looked a lot like a ladle filled vertical press used for casting aluminum.
Compression molding uses preforms made by an extruder and wink cutter (in
which two blades meet at the center to cut the extrudate to length) or a roller die
and die cutter.

Compression molded water bottles are made from die-cut 3 inch by 6 inch sheets.
One sheet is placed below a core and one sheet of equal size is placed above the
core, and then the top of the mold is lowered by hand or by hoist to near shut.
The mold is then pushed into the press, and the press is hydraulically closed to
full pressure. The mold temperature is about 350 degrees. When the cycle ends
(after about 3.5-4.0 minutes), the press opens and the mold is pulled out toward
the operator. The operator opens the clam shell mold top and leans the top of the
mold back against the press. Exposed is the bottle with the core still inside. While
the bottle is still hot, the operator inserts prongs in between the bottle and the
steel core and stretches the bottle at the neck to free it from the core.
The preforms for compression molded golf ball centers are extruded. The preform
has a 1 inch by 1 inch round slug that stands up in the mold cavity. During the
cycle, the operator loads the jig with slugs and places the jig over the mold. The
preforms are released into the cavity of the mold when the slide tray is pulled.
When the mold is opened, the lower platen lowers and the mold is hydraulically
pushed out to the operator. The heat sheet (all molded parts from that cycle
joined together by a parting line rind (flash)) is then placed in a transfer cart to be
die cut.

Typical tools and geometry produced[edit]

Three types of molds used are the flash plunger-type, straight plunger-type, and
the "landed" plunger-type molds. The flash type mold must have an accurate
charge of plastic and produces a horizontal flash (excess material protruding
from the mold). The straight plunger-type mold allows for some inaccuracy in the
charge of plastic and produces a vertical flash. The landed plunger type mold
must have an accurate charge of plastic, and no flash is produced. Further details
are explained in Ref 3.

See also[edit]

● Matrix molding

References[edit]

● ^ "Moulding | Walker Rubber". Walker Rubber Ltd. Retrieved May 19, 2021.
● ^ "Introduction to Compression Molding". eFunda. Retrieved March 19, 2013.
● ^ "DKM-DH Machine". DKM. Retrieved July 9, 2023.
● ^ "What is Compression Moulding?". Coventive Composites. Retrieved October 1, 2018.

Bibliography[edit]

● Todd, Robert H., Dell K. Allen, and Leo Alting. Manufacturing Processes
Reference Guide. New York: Industrial P, Incorporated, 1993 on page
219-220....
 Wikimedia Commons has media related to Compression molding.

show

● V
● T
● E

Plastics

Category:

Molding processes
This page was last edited on 19 March 2024, at 03:17 (UTC).

Text is available under the Creative Commons Attribution-ShareAlike License 4.0; additional terms may
apply. By using this site, you agree to the Terms of Use and Privacy Policy. Wikipedia® is

Compression molding
8 languages
Article
Talk
Read
Edit
View history
Tools
From Wikipedia, the free encyclopedia

Compression molding - simplified diagram of the process

 Compression molded rubber boots before the flashes are removed.

This article may

require cleanup to
meet Wikipedia's
quality standards.
The specific
problem is: poor
readability. Please
help improve this
article if you can.
(February 2020)
(Learn how and
when to remove this
message)

Compression molding is a method of molding in which the molding material,

generally preheated, is first placed in an open, heated mold cavity. The mold is
closed with a top force or plug member, pressure is applied to force the material
into contact with all mold areas, while heat and pressure are maintained until the
molding material has cured; this process is known as compression molding
method and in case of rubber it is also known as 'Vulcanisation'. [1] The process
employs thermosetting resins in a partially cured stage, either in the form of
granules, putty-like masses, or preforms.

Compression molding is a high-volume, high-pressure method suitable for

molding complex, high-strength fiberglass reinforcements. Advanced composite
thermoplastics can also be compression molded with unidirectional tapes, woven
fabrics, randomly oriented fiber mat or chopped strand. The advantage of
compression molding is its ability to mold large, fairly intricate parts. Also, it is
one of the lowest cost molding methods compared with other methods such as
transfer molding and injection molding; moreover it wastes relatively little
material, giving it an advantage when working with expensive compounds.

However, compression molding often provides poor product consistency and

difficulty in controlling flashing, and it is not suitable for some types of parts.
Fewer knit lines are produced and a smaller amount of fiber-length degradation is
noticeable when compared to injection molding. Compression-molding is also
suitable for ultra-large basic shape production in sizes beyond the capacity of
extrusion techniques. Materials that are typically manufactured through
compression molding include: Polyester fiberglass resin systems (SMC/BMC),
Torlon, Vespel, Poly(p-phenylene sulfide) (PPS), and many grades of PEEK.[2]

Compression molding is commonly utilized by product development engineers

seeking cost effective rubber and silicone parts. Manufacturers of low volume
compression molded components include PrintForm, 3D, STYS, and Aero MFG.

Compression molding was first developed to manufacture composite parts for

metal replacement applications, compression molding is typically used to make
larger flat or moderately curved parts. This method of molding is greatly used in
manufacturing automotive parts such as hoods, fenders, scoops, spoilers, as
well as smaller more intricate parts. The material to be molded is positioned in
the mold cavity and the heated platens are closed by a hydraulic ram. Bulk
molding compound (BMC) or sheet molding compound (SMC), are conformed to
the mold form by the applied pressure and heated until the curing reaction
occurs. SMC feed material usually is cut to conform to the surface area of the
mold. The mold is then cooled and the part removed.

Materials may be loaded into the mold either in the form of pellets or sheet, or the
mold may be loaded from a plasticating extruder. Materials are heated above their
melting points, formed and cooled. The more evenly the feed material is
distributed over the mold surface, the less flow orientation occurs during the
compression stage.[3]

Compression molding is also widely used to produce sandwich structures that

incorporate a core material such as a honeycomb or polymer foam. [4]

Thermoplastic matrices are commonplace in mass production industries. One

significant example are automotive applications where the leading technologies
are long fibre reinforced thermoplastics (LFT) and glass fiber mat reinforced
thermoplastics (GMT).
In compression molding there are six important considerations that an engineer
should bear in mind[citation needed]:

● Determining the proper amount of material.

● Determining the minimum amount of energy required to heat the
material.
● Determining the minimum time required to heat the material.
● Determining the appropriate heating technique.
● Predicting the required force, to ensure that shot attains the proper
shape.
● Designing the mold for rapid cooling after the material has been
compressed into the mold.

Process definition[edit]

Compression molding is a forming process in which a plastic material is placed

directly into a heated metal mold then is softened by the heat and therefore
forced to conform to the shape of the mold, as the mold closes. Once molding is
completed excess Flash may be removed. Typically, compression molding
machines open along a vertical axis.

Process characteristics[edit]

The use of thermoset plastic compounds characterizes this molding process

from many of the other molding processes. These thermosets can be in either
preform or granule shapes. Unlike some of the other processes we find that the
materials are usually preheated and measured before molding. This helps to
reduce excess flash. Inserts, usually metallic, can also be molded with the plastic.
As a side note, remember not to allow any undercuts on the shape, it will make
ejection especially difficult. Thermoplastic matrices with an inherent indefinite
shelf-life and shorter cycle molding times are widely used and examples are
shown in Ref 3.

Process schematic[edit]

Compression molding is one of the oldest manufacturing techniques for rubber

molding[citation needed]. The process parameters include molding time, temperature,
and pressure. Usually, a 300-400 ton clamp pressure is used. The typical mold is
shaped like a clam shell with the bottom being the mold cavity. The molding
press looked a lot like a ladle filled vertical press used for casting aluminum.
Compression molding uses preforms made by an extruder and wink cutter (in
which two blades meet at the center to cut the extrudate to length) or a roller die
and die cutter.

Compression molded water bottles are made from die-cut 3 inch by 6 inch sheets.
One sheet is placed below a core and one sheet of equal size is placed above the
core, and then the top of the mold is lowered by hand or by hoist to near shut.
The mold is then pushed into the press, and the press is hydraulically closed to
full pressure. The mold temperature is about 350 degrees. When the cycle ends
(after about 3.5-4.0 minutes), the press opens and the mold is pulled out toward
the operator. The operator opens the clam shell mold top and leans the top of the
mold back against the press. Exposed is the bottle with the core still inside. While
the bottle is still hot, the operator inserts prongs in between the bottle and the
steel core and stretches the bottle at the neck to free it from the core.

The preforms for compression molded golf ball centers are extruded. The preform
has a 1 inch by 1 inch round slug that stands up in the mold cavity. During the
cycle, the operator loads the jig with slugs and places the jig over the mold. The
preforms are released into the cavity of the mold when the slide tray is pulled.
When the mold is opened, the lower platen lowers and the mold is hydraulically
pushed out to the operator. The heat sheet (all molded parts from that cycle
joined together by a parting line rind (flash)) is then placed in a transfer cart to be
die cut.

Typical tools and geometry produced[edit]

Three types of molds used are the flash plunger-type, straight plunger-type, and
the "landed" plunger-type molds. The flash type mold must have an accurate
charge of plastic and produces a horizontal flash (excess material protruding
from the mold). The straight plunger-type mold allows for some inaccuracy in the
charge of plastic and produces a vertical flash. The landed plunger type mold
must have an accurate charge of plastic, and no flash is produced. Further details
are explained in Ref 3.

See also[edit]

● Matrix molding
References[edit]

● ^ "Moulding | Walker Rubber". Walker Rubber Ltd. Retrieved May 19, 2021.
● ^ "Introduction to Compression Molding". eFunda. Retrieved March 19, 2013.
● ^ "DKM-DH Machine". DKM. Retrieved July 9, 2023.
● ^ "What is Compression Moulding?". Coventive Composites. Retrieved October 1, 2018.

Bibliography[edit]

● Todd, Robert H., Dell K. Allen, and Leo Alting. Manufacturing Processes
Reference Guide. New York: Industrial P, Incorporated, 1993 on page
219-220....

Wikimedia Commons has media related to Compression molding.

show

● V
● T
● E

Plastics

Category:

Molding processes
This page was last edited on 19 March 2024, at 03:17 (UTC).

Text is available under the Creative Commons Attribution-ShareAlike License 4.0; additional terms may
apply. By using this site, you agree to the Terms of Use and Privacy Policy. Wikipedia® is

Compression molding
8 languages
Article
 Talk
Read
Edit
View history
Tools
From Wikipedia, the free encyclopedia

Compression molding - simplified diagram of the process

Compression molded rubber boots before the flashes are removed.

This article may

require cleanup to
meet Wikipedia's
quality standards.
The specific
problem is: poor
readability. Please
help improve this
 article if you can.
(February 2020)
(Learn how and
when to remove this
message)

Compression molding is a method of molding in which the molding material,

generally preheated, is first placed in an open, heated mold cavity. The mold is
closed with a top force or plug member, pressure is applied to force the material
into contact with all mold areas, while heat and pressure are maintained until the
molding material has cured; this process is known as compression molding
method and in case of rubber it is also known as 'Vulcanisation'. [1] The process
employs thermosetting resins in a partially cured stage, either in the form of
granules, putty-like masses, or preforms.

Compression molding is a high-volume, high-pressure method suitable for

molding complex, high-strength fiberglass reinforcements. Advanced composite
thermoplastics can also be compression molded with unidirectional tapes, woven
fabrics, randomly oriented fiber mat or chopped strand. The advantage of
compression molding is its ability to mold large, fairly intricate parts. Also, it is
one of the lowest cost molding methods compared with other methods such as
transfer molding and injection molding; moreover it wastes relatively little
material, giving it an advantage when working with expensive compounds.

However, compression molding often provides poor product consistency and

difficulty in controlling flashing, and it is not suitable for some types of parts.
Fewer knit lines are produced and a smaller amount of fiber-length degradation is
noticeable when compared to injection molding. Compression-molding is also
suitable for ultra-large basic shape production in sizes beyond the capacity of
extrusion techniques. Materials that are typically manufactured through
compression molding include: Polyester fiberglass resin systems (SMC/BMC),
Torlon, Vespel, Poly(p-phenylene sulfide) (PPS), and many grades of PEEK.[2]

Compression molding is commonly utilized by product development engineers

seeking cost effective rubber and silicone parts. Manufacturers of low volume
compression molded components include PrintForm, 3D, STYS, and Aero MFG.

Compression molding was first developed to manufacture composite parts for

metal replacement applications, compression molding is typically used to make
larger flat or moderately curved parts. This method of molding is greatly used in
manufacturing automotive parts such as hoods, fenders, scoops, spoilers, as
well as smaller more intricate parts. The material to be molded is positioned in
the mold cavity and the heated platens are closed by a hydraulic ram. Bulk
molding compound (BMC) or sheet molding compound (SMC), are conformed to
the mold form by the applied pressure and heated until the curing reaction
occurs. SMC feed material usually is cut to conform to the surface area of the
mold. The mold is then cooled and the part removed.

Materials may be loaded into the mold either in the form of pellets or sheet, or the
mold may be loaded from a plasticating extruder. Materials are heated above their
melting points, formed and cooled. The more evenly the feed material is
distributed over the mold surface, the less flow orientation occurs during the
compression stage.[3]

Compression molding is also widely used to produce sandwich structures that

incorporate a core material such as a honeycomb or polymer foam. [4]

Thermoplastic matrices are commonplace in mass production industries. One

significant example are automotive applications where the leading technologies
are long fibre reinforced thermoplastics (LFT) and glass fiber mat reinforced
thermoplastics (GMT).

In compression molding there are six important considerations that an engineer

should bear in mind[citation needed]:

● Determining the proper amount of material.

● Determining the minimum amount of energy required to heat the
material.
● Determining the minimum time required to heat the material.
● Determining the appropriate heating technique.
● Predicting the required force, to ensure that shot attains the proper
shape.
● Designing the mold for rapid cooling after the material has been
compressed into the mold.

Process definition[edit]

Compression molding is a forming process in which a plastic material is placed

directly into a heated metal mold then is softened by the heat and therefore
forced to conform to the shape of the mold, as the mold closes. Once molding is
completed excess Flash may be removed. Typically, compression molding
machines open along a vertical axis.

Process characteristics[edit]
The use of thermoset plastic compounds characterizes this molding process
from many of the other molding processes. These thermosets can be in either
preform or granule shapes. Unlike some of the other processes we find that the
materials are usually preheated and measured before molding. This helps to
reduce excess flash. Inserts, usually metallic, can also be molded with the plastic.
As a side note, remember not to allow any undercuts on the shape, it will make
ejection especially difficult. Thermoplastic matrices with an inherent indefinite
shelf-life and shorter cycle molding times are widely used and examples are
shown in Ref 3.

Process schematic[edit]

Compression molding is one of the oldest manufacturing techniques for rubber

molding[citation needed]. The process parameters include molding time, temperature,
and pressure. Usually, a 300-400 ton clamp pressure is used. The typical mold is
shaped like a clam shell with the bottom being the mold cavity. The molding
press looked a lot like a ladle filled vertical press used for casting aluminum.
Compression molding uses preforms made by an extruder and wink cutter (in
which two blades meet at the center to cut the extrudate to length) or a roller die
and die cutter.

Compression molded water bottles are made from die-cut 3 inch by 6 inch sheets.
One sheet is placed below a core and one sheet of equal size is placed above the
core, and then the top of the mold is lowered by hand or by hoist to near shut.
The mold is then pushed into the press, and the press is hydraulically closed to
full pressure. The mold temperature is about 350 degrees. When the cycle ends
(after about 3.5-4.0 minutes), the press opens and the mold is pulled out toward
the operator. The operator opens the clam shell mold top and leans the top of the
mold back against the press. Exposed is the bottle with the core still inside. While
the bottle is still hot, the operator inserts prongs in between the bottle and the
steel core and stretches the bottle at the neck to free it from the core.

The preforms for compression molded golf ball centers are extruded. The preform
has a 1 inch by 1 inch round slug that stands up in the mold cavity. During the
cycle, the operator loads the jig with slugs and places the jig over the mold. The
preforms are released into the cavity of the mold when the slide tray is pulled.
When the mold is opened, the lower platen lowers and the mold is hydraulically
pushed out to the operator. The heat sheet (all molded parts from that cycle
joined together by a parting line rind (flash)) is then placed in a transfer cart to be
die cut.
Typical tools and geometry produced[edit]

Three types of molds used are the flash plunger-type, straight plunger-type, and
the "landed" plunger-type molds. The flash type mold must have an accurate
charge of plastic and produces a horizontal flash (excess material protruding
from the mold). The straight plunger-type mold allows for some inaccuracy in the
charge of plastic and produces a vertical flash. The landed plunger type mold
must have an accurate charge of plastic, and no flash is produced. Further details
are explained in Ref 3.

See also[edit]

● Matrix molding

References[edit]

● ^ "Moulding | Walker Rubber". Walker Rubber Ltd. Retrieved May 19, 2021.
● ^ "Introduction to Compression Molding". eFunda. Retrieved March 19, 2013.
● ^ "DKM-DH Machine". DKM. Retrieved July 9, 2023.
● ^ "What is Compression Moulding?". Coventive Composites. Retrieved October 1, 2018.

Bibliography[edit]

● Todd, Robert H., Dell K. Allen, and Leo Alting. Manufacturing Processes
Reference Guide. New York: Industrial P, Incorporated, 1993 on page
219-220....

Wikimedia Commons has media related to Compression molding.

show

● V
● T
● E
 Plastics

Category:

Molding processes
This page was last edited on 19 March 2024, at 03:17 (UTC).

Text is available under the Creative Commons Attribution-ShareAlike License 4.0; additional terms may
apply. By using this site, you agree to the Terms of Use and Privacy Policy. Wikipedia® is