Product Design

Plastics

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 Learning objectives

To understand where plastics originate and the

Learning objectives

differences between natural and synthetic plastics.

To learn how thermoplastics and thermosetting
plastics are structured and the properties of plastics
from both groups.
To realize that the properties of plastics can be
changed using additives.
To understand that most, but not all, plastics can be
recycled.
To become familiar with the range of hand tools and
industrial processes used to manufacture plastic
products.

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Background on plastics

Plastics are probably the most widely used materials in

manufacturing today. This is because of the huge variety of
plastics available and their different properties.
All plastics are made by either natural or synthetic means.

Natural plastics: used since 2000BC

obtained from natural sources
such as trees and milk.

Synthetic plastics: produced from coal, gas and oil

chemically manufactured.

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Examples of natural plastics

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Sources of synthetic plastics

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Polymerization

Plastics are often called polymers which means ‘many

parts’.
The monomer molecule is the base unit of polymers.
It combines together with other monomer molecules to
form chains of molecules called polymers.
As the polymer grows, its melting point increases and it
becomes more rigid because of the links between each
monomer molecule.

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Categories of plastics

Plastics can be broken down into two categories:

thermoplastics and thermosetting plastics.
Thermoplastics:
are mostly recyclable
can be shaped and reshaped
under heat
have plastic memory (will
return to their original shape
when reheated)
are made of long polymer
chains with few cross links, individual monomer molecule
making them flexible under
heat.
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Categories of plastics

Thermosetting plastics:
are initially set by heat
cannot be reshaped once set
are extremely strong and
durable
are common in powder or
resin forms
consist of polymer chains
with strong bonds between
individual monomer molecule
each chain. This is a more rigid
structure than a thermoplastic
and heat improves the
strength of the links.

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Types of thermoplastics

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Types of thermosets

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Stock forms of plastic

Plastic is available in several raw forms – powder,

granules, liquid, rods, tubes, sheets and foam. Each form
of plastic is suitable for different manufacturing
processes depending on the type of equipment used, the
cost of the plastic, the scale of production and the
properties of the finished product.

Polystyrene sheets are

used for vacuum forming.

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Changing the properties of plastics

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Recycling plastic – using SPI codes

Most, but not all, plastics can be recycled. However, it is

vital that different types of plastic are not mixed when
melted down.
The plastic industry has developed a series of SPI codes
that detail which plastics are used in a product.
Almost everything made from plastic should now be marked
with a code. These markers do not mean that the plastic
has been recycled or that it can be recycled, they simply
identify the type of plastic the product is made from.

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Recycling plastic – using SPI codes
This is a list of the different SPI resin identification codes:
Type 1 – PETE ( Water containers)

Type 2 – HDPE (Toys, milk and detergent bottles)

Type 3 – PVC (Blister packs, sandwich/salad packs)

Type 4 – LDPE (Plastic bags, shrink wrap)

Type 5 – PP (Food containers, bottle tops, furniture)

Type 6 – PS (Disposable utensils, meat packaging)

Type 7 – OTHER (No recycling potential – land fill only)

Can you identify the abbreviated plastic names?
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Working with plastics – hand tools

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Working with plastics – other processes

Plastics can also be worked in other ways.

Hot wire
Oven strip heater

Scroll saw

Drill

Buffer

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Vacuum forming
When plastic is used to make a large number of identical
products, industrial processes are used. Specialized
machines are used to mass produce products. Press play
to see a video of the vacuum forming process.

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Injection moulding

What similarities and differences can you identify between the

vacuum forming and injection moulding processes?
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Blow moulding

What similarities and differences can you identify between the

blow moulding and vacuum forming processes?
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Line bending

What products can you think of that have been

manufactured using a strip heater?
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Compression moulding

What is the difference between male and female moulds?

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Extrusion

Can you think of any other products that are

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manufactured using extrusion?
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Finishing techniques
Plastics have excellent surface qualities. As they are
self-finishing, plastics require little or no surface finish.
However, when designers want a specific colour or texture,
spray paints can be used.
Use wet and dry paper (wet) to smooth the surface down
and create a ‘key’ for the primer to grip to.
Primer is used to create an undercoat to protect the plastic
and provide a good surface finish for the top coat. The
primer should be rubbed down using wet and dry paper
between coats.
Top coat is applied once the primer has completely
hardened. There are different surface textures; gloss, matt
and metallic being the most common. Top coat is applied in
several layers to build up a thick, tough surface layer on the
top of the primer.
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Key points
Plastics are the most widely used materials in
manufacturing today.
Thermoplastics include acrylic, polythene and
Key points

polystyrene. They can be reshaped by heat.

Thermosetting plastics are extremely strong and
durable, and include epoxy resin and melamine
formaldehyde.
Most plastics can be recycled. Plastic products are
marked with SPI codes to tell you which plastics they
are made from.
Plastics can be worked with hand and machine tools.
When large numbers of identical products are required,
industrial processes, such as injection moulding and
vacuum forming, are used.
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