Plastic Processing

Extrusion Compression Moulding

Injection Moulding Calendering

Blow Moulding Strip Heating

Vacuum Forming Rotational Moulding

Extrusion
 Extrusion
Continuous process  used to produce both solid and hollow products
that have a constant cross-section. E.g. window frames, hose pipe,
curtain track, garden trellis.
Thermoplastic granules are fed from a hopper by a rotating screw
through a heated cylinder.
The tapered screw compacts the plastic as it becomes elasticised.
The die which is fitted to the end of the extruder barrel  determines
the cross-section  of the extrusion.
Thicker cross-sections are extruded more slowly as more time is
required  for the initial heating and subsequent cooling of the larger
quantities of material which are involved. As the extrusion leaves
the die it is cooled  by passing through a cooling trough (below)
containing cold water.
 Extrusion
• Produces tubes, rods and other shaped continuous
form lengths.
• Heated polymer is fed into shaped die by a screw.
 process
• rotates in a close-fitting fixed steel barrel
• barrel is heated and accurately temperature
controlled
• plastics materials are heated, compressed, sheared
and mixed as they are moved along the screw
• plastics materials emerge as a homogenous melt at
high pressure off the end of the screw
• melt is forced through the extrusion die
• sizing and cooling equipment
• marking equipment
• measuring and testing equipment
• cutting and trimming equipment
• winding and coiling equipment
 Advantage
• Low Cost
• Flexibility
• Post-Extrusion Alterations
• Continuous
• High production volumes
• Many types of raw materials
• Good mixing (compounding)
 DISADVANTAGE

Prize Variances
Product Limitation
 Applications
• Tubing, monofilaments, stock shapes (rods,
plates, tubes etc), sheeting
• Loose tubes for fibre optic cables
• Profiles, pipes
• High temperature automotive wiring
 Materials used in Extrusion
This extrusion is part of a window seal made from
thermoplastic elastomer (TPE).
Injection Moulding
Powder or granules from a hopper
into a steel barrel with a rotating
screw. The barrel is surrounded by
heaters The screw is forced back as
plastic collects at the end of the
barrel .

Once a sufficient charge of  melted

plastic has accumulated a hydraulic
ram forces the screw forward
injecting the thermoplastic through
a sprue into the mould cavity.
 Injection Moulding
Pressure is kept on the mould until
the plastic has cooled sufficiently
for the mould to be opened and the
component ejected.

Materials used
Normally thermoplastics are used in this process although a
few thermosetting plastics can also be injection moulded.
Toy made from high impact polystyrene (HIPS).
Feed screw filled
Polymer Injection
Component Ejected
 Injection Moulding
 A measured amount of molten thermoplastic is driven
by a ram past a heating system into the mould.
 The mould is split to allow finished object to be
removed after cooling.
Rotary table blow molding
 Parts of Injection Moulding Machine

• A – split mould
• B – heater
• C – hopper
• D – hydraulic
ram
• E – torpedo
(spreader)
• Injection moulding produces accurate and
complex products with high quality finish.
• Production is fast with little waste.
• Wide range of products including bowls,
buckets, containers, toys, electrical parts and
car parts.
 Process
• Pellets placed in hopper
• Pellets fall into barrel through throat
• Pellets packed to form solid bed – air forced out through
hopper
• Pellets melted by mechanical shear between barrel and screw
• Melted plastic forms shot in front of screw
• Screw moves forward to inject plastic into mold cavity
• Part cools and solidifies
• Mold opens
• Ejection pins move forward to eject part
• Mold closes
• Process starts again
 Advantages
• Fast production.
• Low labour costs.
• Design flexibility.
• High-output production.
• Multiple materials can be used at the same time.
• Can be used to produce very small parts.
• Leaves little post-production scrap.
• Ability to include inserts.
• Good colour control.
• Good product consistency.
• Good dimensional control.
 Disadvantages
• High initial tooling and machinery cost.
• Part design restrictions.
• Small runs of parts can be costly
Plastic Injection Molding Applications
• Aerospace components,Automotive components
• Cable assemblies
• Computer electronics
• Electronics components
• Engineering prototypes
• Instrumentation
• Marketing samples
• Material quality testing
• Medical & dental products
• Medical laboratories
• Model shops, toys, hobby
 Blow Moulding

• A simple explanation of the principle of

blow molding is similar to inflating a
balloon Blow molding is a process used to
produce hollow objects from thermoplastic
Blow Molding

http://www.krk.co.jp/en/tech/blow.htm

l
 Introduction
• Blow Molding
– Modified extrusion and injection-molding process
• Characteristics
– Hollow thin-walled parts of various sizes
– High production rates
– Low cost for making beverage and food containers

December 09, 2006 Mitchel Plamondon

 Blow Moulding

1. A hollow length of 2. The mould closes.

plastic, called a parison,

is extruded down between
the two halves of the
mould.
Blow Moulding

3. Compressed air is blown into 4. The mould is then opened the

the inside of the parison which moulding ejected and the waste
inflates it, pushing the soft plastic (called flash) is trimmed off
hard against the cold surfaces of with a knife.
the mould.
 Blow Moulding
• Used to make
bottles and hollow
toys.
• Air is blown into a
plastic tube, called a
parison, to take the
shape of the mould.
• PVC and polythene
are often used.
Blow molding process; general steps
• Melting the resin- done in extruder
• Form the molten resin into a cylinder or tube
(this tube is called parison)
• The parison is placed inside a mold, and
inflated so that the plastic is pushed outward
against the cavity wall
• The part is allowed to cool in the mold and is
then ejected
• The part is trimmed
 Methods

There are two types of blow molding

• Extrusion Blow Molding

• Injection Blow Molding

– Injection Molding gives rise to a third
process called stretch blown molding

December 09, 2006 Mitchel Plamondon

 Extrusion Blow Molding

(1)extrusion of parison
(2)parison is pinches at the top and sealed at the bottom around a
metal blow pin as the two halves of the mold come together
(3) the tube is inflated so that it takes the shape of the mold
cavity
(4) mold is opened to remove the solidified part.

Mitchel Plamondon
 General steps
• The parison is extruded vertically in
downward direction between two
mold halves.
• When the parison reaches the required
length the two mold halves close
resulting in pinching the top of parison
end and sealing the blow pin in the
bottom of the parison end.
• Parison is inflated by air blown
through the blow pin, taking a shape
conforming that of the mold cavity.
The parison is then cut on the top.
• The mold cools down, its halves open,
and the final part is removed.
 Shaping hollowed products such as bottles
• The production line uses an annulus die attached
to the end of a reciprocating screw extruder.
• A molten polymer is vertically extruded through
the die and placed and clamped in between two
halves of a cold mould, the shape of the mould
usually being the shape of the desired product.
• The extrudate from the die called “parison” is cut
off from the die using a hot knife and is then
inflated with compressed air and the product
solidified as the inflation continues
• By opening the mould, the finished
product is ejected.
• The process can be discontinueous and
continuous. In the continuous process,
second parison is extruded through the
die whilst the first one in being inflated
with air. In the continuous process,
second parison is extruded through the
die whilst the first one in being inflated
with air.
 Problems
The continuous nature of the Six ways to solve the problem of
interference:
extrusion process is a problem
with extrusion blow molding. 1. Intermittent Extrusion Blow
Molding
2. Continuous Extrusion Blow
Molding
3. Accumulator Head (Ram
Extension)
4. Rising Mold System
5. Parison Transfer System
6. Multiple-Mold System

Figure: Parison transfer system for continuous extrusion blow

molding.

December 09, 2006 Mitchel Plamondon

 Rotary blow molding wheel
Intermittent Extrusion Blow Molding
• Stop the extrusion of the parison
while the part is cooling in the
mold.

Continuous Extrusion Blow Molding

• An accumulator receives the
material from the extruder and the
creates the parison as needed.

Accumulator Head or Ram Extrusion

• The extruder output flows into a reservoir that is external to the extruder
itself. A ram pushes the resin out of the reservoir and through the die that is
mounted at the end of the accumulator to create the parison.
 Rotary table blow molding
• When the mold closes on the parison and
air injection has occurred, the mold is
moved off to the side. The pinching off the
mold creates a break point in the parison
so that when the mold moves aside, the
parison is not disturbed.
Parison Transfer System
• The parison is cut from the die by a knife
and transferred by a mechanical arm to a
mold where it is blown, cooled, and
ejected.
Multiple-Mold System
• Several Molds are mounted to a rotating
wheel. While one mold is closing the
capture the parison, the mold ahead is in a
position for the blowing of the part, and
other parts are closed for cooling, and
further up a mold opens to eject the part Plastics Materials and Processing
Rotary table blow molding
• Advantages
1)Low tooling and Die cost
2)Fast production
3)Ability to mould complex part

Disadvantages
1)Limited to hollow parts
2)Low strength
 Application
• high density polyethylene-Stiff bottles, small
drum, toys, cases
• Low density polyethylene- flexible bottel
• Polypropylene- High temperatures bottle
• polyvinyl chloride – oil contener
 Injection Blow Molding
• In this method, a parison is produced by injecting a polymer into a
hot injection mold around a blow tube or core rod.
• Then the blow tube together with the parison is removed from the
injection mold and transferred to a blow mold.
• Air is injected under pressure blowing the polymer against the mold
walls where it cools and freezes as with extrusion blow molding.
 Injection Blow Molding

http://www.sinotech.com/products/plastic/blowMolding.htm

Injection blow molding:

1. Parison is injection molded around a blowing rod

2. Injection mold is opened and parison is transferred to a blow mold
3. Soft polymer is inflated to conform to a blow mold
4. Blow mold is opened and blown product is removed.
• Injection Blow Molding is a more accurate
and controllable process as compared to the
Extrusion Blow Molding.
• It allows producing more complicated
products from a wider range of polymer
materials.
• However production rate of Injection Blow
Molding method is lower than that of
Extrusion Blow Molding.
 Advantages -
• 1. Accurate shaping of the neck. 
2. A High level of dimensional accuracy. 
3. Mini weight tolerance. 
4. The highest quality surface finish. 
5. Production absolutely free from waste. 
6. Crystal clear containers for pharmaceutical 
application. 
7. Finished bottle without weld line and scrap. 
8. Secondary /finishing operation can be avoided. 
 Disadvantages  
1. The preform design generally establish the core rod length &
diameter. 
2. The process is more expensive than extrusion blow moulding. 
3. Compromise between preform wall thickness and blow up ratio. 
4. The ratio of the maximum wall thickness to minimum wall
thickness across a preform cross-section should be less than 1.5 to
prevent weld lines. 
5. Preform thickness greater than 6 mm is unstable during blowing
since the thick section cannot be properly conditioned. 
6. The technique is not suitable for manufacturing of bottles with
handles such as those used for detergent bottles. 
7. Since the injection moulds are required for each preform type of
shape, the process is more expensive the extrusion blow moulding
 Extrusion
• Bottles over ½ pound
• Tooling costs are 50% to 75
% less
• Generates 20 to 30% scrap
• Additional machinery needed
to grind scrap
• Total cycle time is shorter
• Wider choice of resins
• Greater flexibility in part
design
December 09, 2006 Mitchel Plamondon
Injection
• Long runs and smaller
bottles
• No trim scrap
• Higher accuracy in the
final part
• Uniform wall thickness
• No seam lines or pinch
marks
• Better transparencies
• Improved mechanical
properties
 Stretch Blow Molding
• Stretch Blow Molding involves injection molding of
a parison, which is then stretched in the downward
direction by means of the blow tube.
• In this method biaxial molecular orientation is
produced. The specific molecular orientation
provides higher mechanical strength, rigidity and
transparency of the material.
• That is why this method is used Polyethylene
Terephtalate for manufacturing containers for
carbonated beverages.
Stretch Blow Molding
Stretch Blow Molding Stretch blow molding produces
a part with biaxial molecular
alignment. In the process a
preform, or parison, elongated
http://plastics.turkavkaz.ru/processes/molding/blow-molding/stretch/
mechanically in the mold and
than expanded radially in a
blowing process. A desirable
resulting molecular orientation
yields a material with increased
strength. This means that
A: Stretch-Blown Pin; B: Air Entrance; C: Mold Vents; D: Preform;
E: Stretch Rod Extended; F: Cooling Channels
products that are strength-based
designs can be produced using
less material than if they were
/
to be produced using simpler
blow molding techniques.

December
09, 2006 Mitchel Plamondon
 Materials Considerations
One critical requirement is that the
polymer must have good melt
strength.
The common blow molded plastics
are:
• Polyolefins
– HDPE
– LDPE
– Polypropylene (PP)
http://upload.wikimedia.org/wikipedia/en/2/2a/Soft_drink_shelf.JPG
• PVC
PET bottles are excellent barrier materials and are
• PET widely used for soft drinks

December 09, 2006 Mitchel Plamondon

Materiasl used in blow moulding
High density polyethylene (HDPE) and low density polyethylene
(LDPE)  are both commonly used for blow moulding as are other types
of thermoplastics. The thermoplastic used in blow moulding  needs to be
more viscous (flow less easily) than that used for injection moulding as
the parison must  retain its form before the mould closes around it.
Used extensively to make bottles and other lightweight , hollow parts
Polyolefins
ADVANTAGES
The polyolefins are easy to process and have the advantage
of good electrical properties, moisture resistance, and low
cost.
DISADVANTAGES
Sensitive to oils and can have stress crack problems

PROCESSING PARAMETERS
These resins are usually blow molded in the range of 320o
– 410oF. Mold temperatures should range from 50o –
100oF.
December
09, 2006 Mitchel Plamondon
 Polyvinyl Chloride (PVC)
ADVANTAGES
Very desirable properties of clarity, smooth surface low
glass and aroma permeation, high stiffness with low wall
thickness, high chemical resistance, and easy labeling and
printing
DISADVANTAGES
Very temperature sensitive, therefore not normally injection
blown because the process requires two heat cycles
PROCESSING PARAMETERS
o o
Typical melt temperature range for PVC is 375 – 420 F.

December
09, 2006 Mitchel Plamondon
 Polyethylene terephthalate

ADVANTAGES
Easily recycled, very lightweight, it makes a good gas and
fair moisture barrier. It is strong and impact-resistant. It is
naturally colorless and transparent.
DISADVANTAGES
Have to be careful to avoid a temperature that is two high
or acetaldehyde forms.

PROCESSING PARAMETERS
Temperature range for PET to blow mold is 200o – 212oF.
Mold temperatures should be in the range of 35o – 40oF
December
09, 2006 Mtchel Plamondon

ADVANTAGES
This process lends itself to
any designs involving
hollow shapes. Equipment
availability is good in most
geographical locations. Can
save tooling dollars over
injection molding.
December
09, 2006
Conclusion
RAW APPLICATIONS
MATERIALS All types of bottles, toys, air
ducts for automobiles,
Most commodity grade and chemical & gasoline tanks,
engineering grade resins may
household goods. Can be
be blow molded. The obtained from these blow
viscosity of the plastic must
molding processes.
be high to keep the parison
from stretching too much
prior to mold closure.
DISADVANTAGE
S
Cycle times are slower than
injection molding. Piece
prices are higher than
injection molding.
Mitchel Plamondon
 Thermoforming

• Thermoforming is a manufacturing
process where a plastic sheet is heated to a
pliable forming temperature, formed to a
specific shape in a mold, and trimmed to
create a usable product. 
• Types of Thermoforming

– Vacuum forming
– Billow Drape forming
– Free forming
– Match-Mold forming
– Pressure forming
Vacuum Forming

1. Mould is attached to a platen 2. Once the thermoplastic sheet is

(support plate). The platen and softened enough (reaches a plastic
mould are then lowered and a state) then air is blown in to raise  the
rigid thermoplastic sheet material sheet in a slight bubble before the
is clamped onto an air tight  platen is raised bringing the mould
gasket and usually heated from into contact with the plastic.
above.
 Vacuum Forming

3. trapped air  remaining between 4. Once the plastic sheet has cooled
the platen and the heated plastic down to below it's freeze point the air
sheet is then evacuated by a flow is reversed to lift the forming off
vacuum pump. Atmospheric the mould and the mould lowered
pressure acting over the top surface
completes the forming process by
pressing  the plastic sheet onto the
mould.
Materials used in Vacuum forming

Many types of thermoplastics are suitable for vacuum

forming. The most popular is High Impact Polystyrene
(HIPS). It is relatively cheap, comes in a wide range of
colours and is easy to form. This process is used to
manufacture a variety of  products in thermoplastic
materials. These products range in size from garden pond
liners to food trays used in supermarkets.
 Vacuum Forming
• Plastic sheet is
clamped and heated.
• Heat is removed and
pattern raised.
• Vacuum forces the
sheet onto the pattern.
• The sheet is removed
and trimmed.
Drape forming
 Drape forming

• Drape forming is similar to vacuum

forming. This process involves “draping” a
hot plastic sheet over a mold of the desired
shape and allows the plastic to cool and
harden to take shape. Drape forming is
widely used for large panels that require a
more gradual bend than parts resulting from
other processes
Free forming
 Free forming

• Billow or free bubble forming Does not use a

mold
• The sheet is heated to its forming
temperature, then air pressure is applied
against the sheet, and the sheet expands
• As the bubble expands it touches a shut off
device for the air, controlling the final size of
the bubble
 Match-Mold forming/
Mechanical thermoforming
 Pressure forming
• Pressure forming uses both air pressure to
push the soft, heated plastic more tightly
against the mold giving the part sharp
detail.
Pressure forming
Compression Moulding
1. The mould is charged with a
measured amount of powder or
granules ready to be compressed.
Sometimes plastic charge is first
compacted into a shape called a
preform.
2. When  the two halves of the mould
are  brought together the plastic
material is forced under compression
to flow rapidly around the cavity. heat
from the platens causes the plastic to
cure resulting in a permanent change
in shape.
 Compression Moulding
The component is
ejected from the
mould and any
excess material
formed at edges
(flash) is removed.

Materials used.
Typical thermosetting plastics used in
compression moulding are urea formaldehyde
and phenol formaldehyde.
Compression Moulding
• Thermoset plastics are shaped with heat and
pressure causing cross-linking.
• The polymer can be in powder or slug (cube) form.
• Products such as electrical fittings, saucepan
handles and bottle tops are often formed out of
formaldehyde plastics.
• High quality finishes are achieved with only the
removal of ‘flash’ (excess material usually at the
mould split) for finished products.
 Transfer Moulding
Thermoset polymers can be formed when a preset
amount of material is placed in a separate cavity and
heated. A plunger moves the material into the shaped
mould with high pressure.
Calendering
 Calendering
Involves rolling out a mass of premixed plastics material between large rollers
to form a continuous and  accurately sized film.
The process begins with the ingredients being blended and fluxed in a mixing
mill at approx.100°C. Nip rollers control the thickness of the sheet material
can be gradually reduced in thickness. Rolls of semi-rigid PVC which will be
used to manufacture transparent A4 folder 'pockets'.

Materials used
The main material used is PVC, others include ABS and cellulose acetate.
PVC ranges from flexible to rigid and the final product is composed of a
number of basic materials which must be combined in a uniform mixture of
measured ingredients. These ingredients include a resin of a specified
molecular weight, stabilisers, lubricants, reinforcing materials, colorants and
plasticisers.
 Rotational Molding

• Also known as rotomolding or rotocasting

• Process for manufacturing large, hollow,
one-piece plastic products
Rotational Moulding
1. A measured weight of
thermoplastic is placed inside a
cold mould. The mould is then
closed  and moved into an oven
chamber

2. heated to a temperature of 230-

400 C whilst being rotated around
both vertical and horizontal axes.
As it rotates the mass of powder at
the bottom of the mould fuses and
sticks to the mould surface.
 Steps in rotational moulding

• 1.CHARGING THE MOULD

• 2. HEATING AND ROTATIONAL
PROCESS
• 3.Cooling of mould and De molding
Rotational Moulding
3. the mould moves into
a cooling area  or
chamber where it is
cooled by air or water
jets.

4. The hollow moulding

can be removed as soon
as it is cool enough to
hold its shape.
 Advantages
• A hollow part is made in a single piece with no
weld lines or joints
• Product essentially stress-free
• The molds are relatively inexpensive
• There is no material wastage in this molding
process.
• It is of low cost with respect to the other
molding process.
• Low residual stress
 Disadvantages
• The manufacturing times are long.
• The choice of molding materials is limited
• There is chance of air trapping in the
mould.
• Some geometrical features (such as ribs) are
difficult to mold
Materials used

90% of rotational mouldings are made from polyethylene

(PE), used mainly to manufacture hollow shaped products
such as footballs, road cones and storage tanks up to 3m³
capacity.
 PROCESSING PLASTICS
• Calendering – produces sheets by rolling
into shape.
• Lamination – layers of materials (eg paper,
cloth) are bonded with a resin into a strong
solid structure, often with heat and pressure.
• Foaming – expansion into sponge-like
material by a foaming agent.