C&G 2850 L2 U203

Principles of manufacturing technology

(K/503/0175)
Plastics

1. Extraction of raw materials (largely crude oil and

natural gas, but also coal) – these are a complex
mixture of thousands of compounds that then need to
be processed.
2. Refining process transforms crude oil into different
petroleum products – these are converted to yield
useful chemicals including “monomers” (a molecule
that is the basic building blocks of polymers). In the
refining process, crude oil is heated in a furnace, which
is then sent to the distillation unit, where heavy crude
oil separates into lighter components called fractions.
One of these, called naphtha, is the crucial compound
to make a large amount of plastic. However, there are
other means, such as using gas.
3. Polymerisation is a process in the petroleum
industry where light olefin gases (gasoline) such as
ethylene, propylene, butylene (i.e., monomers) are
converted into higher molecular weight hydrocarbons
(polymers). This happens when monomers are
chemically bonded into chains
Thermosetting and Thermoplastics

Thermosetting plastics and thermoplastics are both polymers, but they

behave differently when exposed to heat. Thermoplastics can melt under
heat after curing while thermoset plastics retain their form and stay solid
under heat once cured.
Because thermoplastics have a low melting point, they are ideal for
applications that use recycled materials. Thermoset plastics, in contrast,
are able to withstand high temperatures without losing their shape,
making them more durable.
Aesthetically, thermoplastics are seen as superior to thermoset
polymers, however thermosetting materials are still deemed to have
better aesthetics than alternatives such as metals. These materials allow
for in-mould painting or coating, including spraying coatings directly into
the mould before the thermoset polymers are injected into it. This
technique offers better adhesion to the material and prevents chipping,
cracking or flaking, even under harsh weather conditions.