Prepared By- Chaudhari M.

M
SVCP (Sinhgad), PUNE (INDIA)
Dept. of Mech. Engg.
 Contents
 Introduction
 Properties of plastics
 Types of plastics
 Plastic Moulding methods
 Compression Moulding
 Injection moldings
 Blow Moulding
 Extrusion Moulding
 Vacuum forming's
 Calendaring
Mr. Chaudhari M.M
 Introduction
 Plastic is material consisting of any of a wide range of synthetic or semi-
synthetic organic compounds that are malleable and so can
be molded into solid objects.
 Plastic moulding is the process of shaping plastic using a rigid frame or
mould.
 The technique allows for the creation of objects of all shapes and sizes
with huge design flexibility for both simple and highly complex designs.
 A popular manufacturing option, plastic moulding techniques are
responsible for many car parts, containers, signs and other high volume
items.
 The underlying concept of plastic moulding is placing liquid polymer into
a hollow mould so that the polymer can take its shape, often with various
ranges of pressure and heat required.
 There are different plastic moulding techniques available to accomplish
this including rotational moulding, injection moulding, blow moulding,
shell moulding and compression moulding to name just a few.
 Each technique has its benefits and is best suited for the creation of
specific items.
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Classification of plastics

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 Types of plastics
 Thermoplastics which are softened by heat and can be
moulded. (Injection moulded, blow moulded or vacuum
formed). Good examples are acrylic, polypropylene,
polystyrene, polythene and PVC.

 Thermosets which are formed by ha heat process but are

then set (like concrete) and cannot change shape by
reheating. Good examples are melamine (kitchen
worktops), Bakelite (black saucepan handles), polyester
and epoxy resins.

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Nylon Very strong, nylon can be machined and will take a fine thread. It is also slippery and can be used to
make washers, spacers and bushes.
Nylon was originally developed as a textile but is available in many forms with vastly different
properties.
Acrylic Comes in a range of thicknesses, colours and can be opaque or transparent. There are two type of
acrylic extruded which is cheaper and very "plastic" and cast which machines better but is harder
and less flexible. Acrylics are available in a range of colours and can be opaque, translucent or
transparent. They are available in sheet, rod, and tube for use in injection moulding, extrusion and
vacuum forming.
PVC and Stiff, hard,tough lightweight plastic. uPVC is stabilised for outside use ans is uded for plastic
uPVC windows and plastic pipes. Plasticised PVC is used for flexible applications such as insulating -
cables.
Polythene This plastic has a range of uses from food packaging to gas pipes. The plastics can be injection
moulded or extruded and is available in two forms. High-density polyethylene (HDPE) is a hard
rigid plastic. A low-density grade ( LDPE )is tough and flexible.
Polypropylen Polypropylene is a tough, cheap plastic, it has a slightly waxy feel. It can be bent repeatedly without
e breaking. Used for Medical equipment such as syringes, stacking chairs (chairshell is
polypropylene), suitcases with integral hinges,
Polycarbonate Used for making eye protection, machine guards and riot shields. It is not as hard as acrylic and can
be cut easily but it will absorb impacts.
Bakelite A thermosetting plastic. Dark brown. Used as a composite reinforced with paper or cloth. Used to
make circuit boards and heat proof insulated parts in the electronics industry.
Epoxy resin A two part mix which can be used as a glue (ARALDITE) or be reinforced with carbon fibre to
produce a very strong and light composite materials which is used in aerospace and Formula 1
Melamine A thermoset very tough and heat resistant. White but can be produced in a full range of colours.
 Properties of Plastics
1. Easy to work and shape
2. Have a low production cost
3. Possess low density
4. Tend to be waterproof.
5. Good electrical insulators.
6. Acceptable acoustic insulation.
7. Good thermal insulation, but most can not
withstand very high temperatures
8. Resistant to corrosion and many chemical factors
9. Some are not biodegradable or easily recyclable,
and if they burn, are highly polluting.
Mr. Chaudhari M.M
 Plastic Moulding methods
1 • Compression Moulding

2 • Injection Mouldings

3 • Blow Moulding

4 • Shell Moulding

5 • Extrusion Moulding

6 • Vacuum Moulding

7 • Calendaring

8 • Rotational Moulding

9 • Transfer Moulding

Mr. Chaudhari M.M

 Compression Moulding
Working Principle:-
 The charge of plastic material
is place in the lower half of a
heated mould cavity.
 The mold cavity is closed with
upper movable half mold &
pressure is applied.
 The pressure is applied along
with heat to compress the
material, which also increases
the polymerization process.
 The mould cavity is then
opened and the final product
is take out.

Mr. Chaudhari M.M

 Cont.….
Advantages:-
1. Production rate is high as the mold
cycle time is in few minutes.
2. Good surface finish with different
texture and styling can be
achieved.
3. High part uniformity is achieved
with compression molding process.
4. Good flexibility in part design is
possible.
5. Extra features like inserts, bosses
and attachment can be molded in
during the processing.
6. Raw material wastage is minimum.
7. Maintenance cost is low.
8. Dimensional accuracy is good.

Mr. Chaudhari M.M

 Cont.….
 Disadvantages
1. Due to expensive machinery and parts, the initial
capital investment associated with compression
molding is high.
2. The process is suitable for high production volume. It
is not economical for making a small number of parts
or for prototyping applications.
3. It is a labor intensive process.
4. Sometimes secondary processing (trimming,
machining) of product is required after compression
molding.
5. Sometimes uneven parting lines are there.
6. There is limitation on mold depth.

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Applications:-
Electronic Components Switches Dishes

Washing machine agitator Home appliances Automotive

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 Injection moldings
Working Principle:-
1. First, we auto loader the plastic material into the barrel, which is surround by heating
elements melting the plastic.
2. In the barrel which is assembled with servo motor screw. The plastic melt will flow
up the screw and under the heating condition get tight and move forward to the
screw head.
3. At the same time, due to the plastic reacting force, the screw will step back. So at the
screw head, it formed a plastic melt saving space to finish its plasticizing process.
Also under the injection hydraulic cylinder force, the screws will injection the
plasticizing melt into the plastic mould through the nozzle. The plastic melt will
remain in the mould cavity through the holding pressure, cooling, process, and then
formed into solid shape ejected out of the mould.

Mr. Chaudhari M.M

Moulding Process Steps:-
 Stage I:-Plastification
 Stage II:- Injection
 Stage III:- Packing
 Stage IV:- Cooling
 Stage V:- Demold
 Stage VI:- Ejection

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Advantages
• Higher production rate
• Close tolerances on small intricate parts
• Minimum wastage of material
• Complex geometry can be easily produced

Disadvantages
• Tooling cost higher
• High setup cost
• Large undercuts can’t be formed

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 Cont.….
 Applications
1. Aerospace
components
2. Engineering
prototypes
3. Household
equipment's
4. Automotive
components
5. Medical and dental
products
6. Computer and
electronics
7. Instrumentation
8. Marketing samples
9. Toys, Model shops etc.
10. Test Specimens
11. Cable assemblies
 Shell moldings

 It is also known as shell mould casting.

 It is an expandable mold casting process that uses a
resin covered sand to form the mould.
 As compared to sand casting, this is process has better
dimension accuracy, a higher productivity rate & lower
labour requirement.
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 Shell moldings Process Steps

Steps I:- Steps II:-

 The first step in the shell mold casting process  The sand mixture is then poured or blown
is to manufacture the shell mold. over the hot casting pattern. Due to the
 The sand we use for the shell molding process reaction of the thermosetting resin with
is of a much smaller grain size than the typical the hot metal pattern, a thin shell forms
green sand mold. This fine grained sand is on the surface of the pattern.
mixed with a thermosetting resin binder.
 A special metal pattern is coated with a
 The desired thickness of the shell is
parting agent, (typically silicone), which will
latter facilitate in the removal of the shell. The
dependent upon the strength
metal pattern is then heated to a temperature requirements of the mold for the
of 175C-370C particular metal casting application.
 Cont.….

Steps III:- Steps IV:-

 The excess "loose" sand is then The shell and pattern are then placed in an
removed after that leaving the both oven for a short period of time, which
shell and pattern from thermosetting causes the shell to harden onto the casting
resins binder. pattern.

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 Cont.….
Steps V:-
Once the baking phase of the
manufacturing process is complete, the
hardened shell is separated from the
casting pattern by way of ejector pins built
into the pattern.
Steps VI:-
Two of these hardened shells, each
representing half the mold for the
casting, are assembled together
either by gluing or clamping.
Mr. Chaudhari M.M
 Cont.….

Steps VII:-
The manufacture of the shell mold is now complete and
ready for the pouring of the metal casting. In many shell
molding processes, the shell mold is supported by sand
or metal shot during the casting process.
Mr. Chaudhari M.M
 Cont.….
 Advantages-
• Excellent Surface Finish
• Dimensional Accuracy is more.
• Hollow Cores: With the shell sands hollow cores and thin profile
moulds can be possible.
• Sand to Metal Ratio is better.
• Ease of Handling
• Resistant to Moisture Pickup
• Excellent Flow-Ability:
• Less Inclusions & High Thermal Stability
• Longer Shelf Life

 Disadvantages-
• High Cost of The Process
• High Tolling Cost
• Cycle Time more Limited Casting Weight.

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 Cont.….
 Application
• Cylinder
heads
• connecting
rods
• Engine blocks
and manifolds
• machine
bases
• Bearing Caps
• Valve body
and Gears.

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Blow Moulding

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 Cont.….
Working Principle:-
1. It is a process of shaping thermoplastic material into one piece,
hollow articles by means of heat & air pressure.
2. A hot thermoplastic tube known as parison is injected in mould cavity.
3. High pressure air in parison& it can be blow out to acquired shape of
die.
4. Then such shape cooling against mould wall, after product is cooled
the mould is opened & part is ejected.

Mr. Chaudhari M.M

 Cont.….
Advantages-
1. Tooling cost is low
2. High production rate
3. Good surface finish can be
obtained.
Disadvantages-
1. It can produce only hollow
articles
2. It is very difficult to control wall
thickness.
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 Cont.….
 Applications:-
1. Bottles
2. Tubes
3. Containers
4. Hollow jars

Mr. Chaudhari M.M

 Extrusion Moulding
Working Principle:-
1. The meaning of extrusion is continuous flow of material through extrusion die.
2. A process consists of feeding the powdered plastic from the hopper into a heated
chamber.
3. A rotating screw carries this material forward and forces it through a heated orifice of
the die.
4. The orifice carries the shape according to required shape of product and then the
product is cooled by water or air blast and carried away by running belt conveyor.
5. It is then cut to required length or coiled.
6. It is basically various shape are throughout like tubes, rods, sheets, films, pipes,
ropes and other profiles.

Mr. Chaudhari M.M

 Cont.….
 Advantages:-
1. Tooling cost is low.
2. Overall cost of part producing is low.
3. Simple & inexpensive equipment's are used.
4. Required simple dies due to process are quickly happen.
 Disadvantages:-
1. It can manufactured uniform cross-sectional area only.
2. Limited complexity of parts.
 Applications:-
1. Wire & cable covering.
2. Coated paper or foil &Variety of windows frame
3. Gasket and channel
4. Pipe and tubing

Mr. Chaudhari M.M

 Vacuum forming
Working Principle:-
 The material is clamped into frame & over the die. Material is heated, begins to
sag, the center of materials move downward & seal against mould.
 Apply atmospheric pressure force the sheet until mold is harden & cooled.
Vacuum is applied to the back of the mold with help of vacuum pump.

Mr. Chaudhari M.M

 Cont.….
Advantages:-
1. Low cost for machining & Tooling
2. Thin & strong part manufactured
3. Capacity of part is high & forming is light.
Disadvantages:-
1. Higher cost of using sheet & film instead of plastic pallet.
2. Trimming is required.
 Applications:-
1. Refrigerator container (Inner Part).
2. Packing container like chocolate, Biscuit & jelly container.
3. Disposal cups & cosmetics packing's.
Mr. Chaudhari M.M
 Calendering

Working Principle:-
 Heated dough paste of plastic compound is passed through a series of hot rollers,
where it is squeezed into the form of thin sheet of uniform thickness.
 Last roll is water cooled & called as chilling rolls.
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 Cont.….
Advantages:-
1. Delivery/output is high.
2. Increase maximum width of sheet or film.
3. Better control of film.
4. Better optical properties also achieved.
Disadvantages:-
1. It is more steps are required.
2. Process are expensive.
 Applications:-
1. Shower curtains, tapes, credit cards.
2. Vinyl floor file, rain wear products.
Mr. Chaudhari M.M
 Rotational Moulding

Working Principle:-
 This process employs the simultaneous rotation of thin walled mould about two
axis, which is perpendicular to each other. After being charged with plastic
material the mould are heated externally while rotating, due to particles melt on
the inner surface of mould.
 Successively layers are deposited until all material are uniformly distributed &
fused, then mould cooled by air or spraying water while still rotating. Mr. Chaudhari M.M
 Cont.….
Advantages:-
1. Dimensional tolerances is much better.
2. It gives good surface finish.
3. Large sized of part can be moulded.
Disadvantages:-
1. It tooling cost is high. So process is expensive.
2. Maintain the temperature level when process running.
3. More steps are required.
 Applications:-
1. Automobile fuel tank, barrel.
2. Large liquid storage tanks like water storage drum.
Mr. Chaudhari M.M
 Transfer Moulding

Working Principle:-
 Its also known as extrusion or Gate moulding. But it is actually modified from of
compression moulding.
 Heat & pressure are applied to the compound separately outside the mould, &
when the letter become fluid it is transferred to the mould under the pressure,
through a sprue & gate, when it cures final product.
Mr. Chaudhari M.M
 Cont.….
Advantages:-
1. Operation is easier.
2. High cavity count.
3. Design flexibility are more.
4. Production cycle is very short.
Disadvantages:-
1. Mould cost is high.
2. Material waste is high
3. Complex mould are increase tooling cost.
 Applications:-
1. Natural gas valve
2. seal
3. Lip or U-cup designed part in hydraulic industry.
Mr. Chaudhari M.M
 Practice Questions
1. State the various types of thermosetting plastics. Explain any one in brief.
2. Explain compression moulding with neat sketch.
3. Explain calendaring with neat sketch. OR What is calendaring operation in plastic
processing? Explain with sketch.
4. State the various materials for processing plastics. OR State any four important properties
of plastics. OR What are different types of plastics and write useful properties of plastics.
OR What are the basic types of plastics? Give two applications of each.
5. Explain the working principle of compression Moulding used for the forming of plastics.
6. Explain with sketch shell moulding process.
7. Explain with neat sketch ‘Injection moulding’. Give its advantages, limitations and
applications.
8. Explain blow moulding process with neat sketch. State its advantages, limitations and
applications also.
9. Write different types of plastic moulding processes and explain extrusion moulding process
with a neat sketch.
10. Explain vacuum forming with neat sketch and give examples.

Mr. Chaudhari M.M

Thank You !!

Mr. Chaudhari M.M