Alexei Volkov
Plastic manufacturing is a process that involves creating plastic products by transforming raw plastic materials into finished products. There are thousands of polymer options, each with its own mechanical property, and a variety of manufacturing processes that can be used to create plastic products. The three main types of plastic processing are injection moulding, blow moulding, and extrusion. Injection moulding is a process where plastic is heated and pushed through a heated chamber by a screw, then forced through a die that creates the final shape of the part. Blow moulding is used to create hollow objects and involves inflating a heated plastic tube inside a mould. Extrusion involves pushing plastic through a die, which creates a cross-section of the final part. Other types of plastic processing include 3D printing, CNC machining, and rotational moulding.
| Characteristics | Values |
|---|---|
| Plastic Processing Types | Injection moulding, blow moulding, extrusion, rotational moulding, and thermoforming |
| Injection Moulding | A high-volume manufacturing method where liquid plastic resin is injected into the empty cavity of a forming die, taking on the shape of the interior surface. |
| Blow Moulding | Used for the production of hollow objects in large quantities, such as bottles, jars, and containers. |
| Extrusion | Plastic is heated and pushed through a heated chamber, then forced through a die that creates the final shape. |
| Rotational Moulding | Used to produce mainly large hollow objects with nearly uniform wall thickness. |
| Thermoforming | A cost-effective process that can be done with simple equipment and is safe due to the absence of harmful chemicals or high temperatures. |
| 3D Printing | Stereolithography (SLA) uses an ultraviolet laser to cure thermoset resin; Selective Laser Sintering (SLS) solidifies thermoset and thermoplastic powders with a laser; Multi Jet Fusion (MJF) builds parts layer-by-layer. |
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What You'll Learn
3D printing/additive manufacturing
3D printing, also known as additive manufacturing (AM), is a plastic processing method that offers several advantages over traditional manufacturing processes. Firstly, it allows for rapid prototyping and iteration, reducing production cycles from days or weeks to just a few hours. This speed advantage is particularly beneficial for creating prototypes and end-use parts.
The technology behind 3D printing has evolved to include various processes, each with its own unique capabilities and applications. One of the most popular and affordable 3D printing processes is Fused Deposition Modelling (FDM), which involves melting plastic filaments and extruding them to form objects. FDM is known for its versatility, being used for both industrial and lower-cost applications. However, it may not offer the same precision as other AM processes.
Another AM process is Stereolithography (SLA), which cures liquid resin to create objects with incredible detail. SLA is often used for creating high-resolution models and prototypes, and it is considered the most popular process for achieving highly detailed results. Selective Laser Sintering (SLS) is another AM process that uses lasers to fuse powdered plastic particles together, allowing for the creation of complex geometries and moving parts without the need for assembly. While SLS offers high-quality results, it requires tedious and time-consuming post-processing, making it less suitable for consumer applications.
The choice of plastic material for 3D printing depends on the specific application and desired properties. Thermoplastics, such as PLA and ABS, are commonly used due to their ease of use, affordability, and flexibility. On the other hand, thermosets, like PVC, are less common in 3D printing due to the health risks associated with melting and the need for specialised air filtration systems.
Additive manufacturing with plastics offers several benefits, including improved design flexibility, reduced material waste, and the ability to create complex structures. It also addresses sustainability concerns by minimising waste and improving structural synthesis. However, one challenge in AM is the need for skilled personnel, as a significant portion of manufacturers' personnel lack AM skills.
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Injection moulding
The first step in injection moulding is clamping. The raw plastic material, in the form of granules or tiny pellets, is fed through a hopper and melted at high temperatures. Once the plastic is soft enough, it is injected under pressure into a single or multi-cavity mould to create the desired shape. The mould consists of two parts: the injection mould, which shapes the plastic, and the ejector mould, which pushes the solidified product out of the machine.
The next step is cooling, which is crucial for ensuring the final product's quality and structural integrity. The plastic parts are left to cool down and solidify before being removed from the mould. The ejection process must be carefully executed to avoid damaging the moulded part. The cooling time can vary depending on factors such as the type of plastic used, the wall thickness of the moulded part, and the presence of cooling channels within the mould tool.
The final step in the injection moulding process is inspection. This step ensures that the moulded parts meet the required specifications and standards. Injection moulding offers various methods to achieve different finishes. For instance, a two-shot or multi-shot mould combines multiple materials into a single finished plastic part, creating softer finishes or incorporating multiple colours. Insert moulding involves placing a pre-moulded form inside a larger mould and pouring molten plastic around it, useful for producing plastic parts with protruding metal bars or screws.
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Blow moulding
The blow moulding process begins with heating a plastic tube, known as a parison or preform, which is then inflated inside a mould. The parison is positioned between two halves of a mould, which defines the final product's shape. Compressed air is then introduced to enlarge the tube, forcing the plastic to stretch and conform to the mould's contours. Once the moulding is finished, the item is cooled, extracted from the mould, trimmed, and prepared for any further processing steps.
There are three main types of blow moulding: extrusion blow moulding, injection blow moulding, and stretch blow moulding. Extrusion blow moulding uses a softened plastic tube as the basis for the moulded product. This tube is installed into the blow moulding machine, and the heated plastic melts to fit the contours of the mould cavity. Injection blow moulding, on the other hand, uses a preformed plastic shape instead of a softened polymer tube. This preformed shape is held in place inside the machine by a core metal pin and then hollowed out by compressed air. Stretch blow moulding is similar to injection blow moulding, but the softened plastic preformed shape is stretched into its final design before compressed air is injected, rather than being held in place by a pin.
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Extrusion moulding
The process involves taking a thermoplastic material, such as powder, pellets, or granules, melting it uniformly, and then pushing the molten plastic through a die under pressure. The die is a metal tool that determines the shape of the final product, with the molten plastic taking on the shape of the die's openings as it exits the extruder. The extruded plastic is then cooled and cut to the desired length. This cooling can be done using several cooling rolls or a water shower. The machinery used in extrusion moulding is relatively cheap as it is less complex.
The process is ideal for making hollow pipes and tubing, such as PVC water and sewer pipes, and very small tubes for medical applications. It can also be used to create drinking straws, fuel lines, and wiring insulation for electrical wires and cables. The plastic can also be formed into thin sheets and films by being flattened out by a set of cooling rolls. These sheets are used in various industries, for example as window panels, protective covers for machines, materials that replace glass, and packaging.
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Thermoforming
Another type of thermoforming is matched mould forming, which involves using male and female moulds to shape the heated plastic sheet. Twin sheet forming involves heating two sheets of plastic and forming and joining them together to produce one item, which is ideal for manufacturing hollow items or items with double walls. Billow forming is a free-form technique that does not use moulds; instead, air jets blast the heated plastic into a bubble until the final design is formed.
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Frequently asked questions
The three main types of plastic processing are injection moulding, blow moulding, and extrusion.
Injection moulding is a high-volume manufacturing method where plastic is melted and injected into the empty cavity of a forming die, taking on the shape of the interior surface. Once the plastic solidifies, the die opens and the finished part is ejected.
Blow moulding is a process where a heated plastic tube is inflated inside a mould to create a hollow plastic part. It is commonly used for creating plastic bottles, toys, and automotive parts.
Extrusion is a process where plastic is heated and pushed through a die, which creates the final shape of the part. The extruded plastic is then cooled and spooled or cut to the desired length.
Other types of plastic processing include 3D printing, rotational moulding, thermoforming, and compression moulding.
