METHODS, PROCESSES, AND EQUIPMENT

FOR PLASTIC & RUBBER MANUFACTURING

METHODS, PROCESSES, AND EQUIPMENT
FOR PLASTIC & RUBBER MANUFACTURING

 PLASTIC
Plastics are the most common materials for producing end-use
parts and products, for everything from consumer products to
medical devices. Plastics are a versatile category of materials,
with thousands of polymer options, each with their own specific
mechanical properties.
A variety of plastic manufacturing processes have been
developed to cover a wide range of applications, part
geometries, and types of plastics. For any designer and engineer
working in product development, it is critical to be familiar with
the manufacturing options available today and the new
developments that signal how parts will be made tomorrow.
METHODS, PROCESSES, AND EQUIPMENT
FOR PLASTIC & RUBBER MANUFACTURING
 How to Choose the Right Plastic Manufacturing Process:
1. Form - Depending on the geometry of a design, manufacturing
options may be limited, or they may require significant design for
manufacturing (DFM) optimization to make them economical to
produce.
2. Volume/Cost - Some manufacturing processes have high front
costs for tooling and setup, but produce parts that are
inexpensive on a per-part basis. In contrast, low volume
manufacturing processes have low startup costs, but due to
slower cycle times, less automation, and manual labor, cost per
part remains constant or decreases only marginally when
volume increases.
3. Lead time - Some processes create first parts within 24 hours,
while tooling and setup for certain high volume production
processes takes months.
 METHODS, PROCESSES, AND EQUIPMENT
FOR PLASTIC & RUBBER MANUFACTURING

 How to Choose the Right Plastic Manufacturing Process:

4. Material - The optimal material for a given application is
determined by a number of factors. Cost must be balanced
against functional and aesthetic requirements. Consider the
ideal characteristics for your specific application and contrast
them with the available choices in a given manufacturing
processes.
 Types of Plastics
Plastics come in thousands of varieties with different base
chemistries, derivatives, and additives that are formulated to cover a
wide range of functional and aesthetic properties.
To simplify the process of finding the material best suited for a given
part or product, let’s look first at the two main types of plastic:
thermoplastics and thermosets.
METHODS, PROCESSES, AND EQUIPMENT
FOR PLASTIC & RUBBER MANUFACTURING

 Types of Plastics
o Thermoplastics
Are the commonly used plastics. The main feature
that sets them apart from thermosets is their ability to go
through numerous melt and solidification cycles without
significant degradation. Thermoplastics are usually supplied
in the form of small pellets or sheets that are heated and
formed into the desired shape using various manufacturing
processes. The process is completely reversible, as no
chemical bonding takes place, which makes recycling or
melting and reusing thermoplastics feasible.
METHODS, PROCESSES, AND EQUIPMENT
FOR PLASTIC & RUBBER MANUFACTURING

 Types of Plastics
o Thermosetting Plastics
In contrast with thermoplastics, thermosetting plastics
(also referred to as thermosets) remain in a permanent solid
state after curing. Polymers in thermosetting materials cross-
link during a curing process that is induced by heat, light, or
suitable radiation. This curing process forms an irreversible
chemical bond. Thermosetting plastics decompose when
heated rather than melting, and will not reform upon
cooling. Recycling thermosets or returning the material back
into its base ingredients is not possible.
 METHODS, PROCESSES, AND EQUIPMENT
FOR PLASTIC & RUBBER MANUFACTURING
 Types of Plastics
o Thermoplastics Common Types
1. Acrylic/PMMA – Poly(methyl 2. Acrylonitrile butadiene styrene
methacrylate) is (ABS) - is a terpolymer made by
a transparent thermoplastic ofte polymerizing styrene
n used in sheet form as a and acrylonitrile in the presence
lightweight or shatter-resistant of polybutadiene. The
alternative to glass. Although proportions can vary from 15%
not a type of familiar silica- to 35% acrylonitrile, 5% to
based glass, the substance, like 30% butadiene and 40% to 60%
many thermoplastics, is often styrene.
technically classified as a type
of glass (in that it is a non-
crystalline vitreous substance

https://www.carvilleplastics.
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properties-cast-acrylic-
pmma/
https://dienamics.com.au/bl
og/lets-talk-about-
acrylonitrile-butadiene-
styrene-abs/
 METHODS, PROCESSES, AND EQUIPMENT
FOR PLASTIC & RUBBER MANUFACTURING
 Types of Plastics
o Thermoplastics Common Types
3. Polyamide – is
a polymer with repeating 4. Polylactic acid (PLA) - is
units linked by amide bonds. a thermoplastic polyester formally
Polyamides occur both naturally obtained by condensation of lactic
and artificially. Examples of acid with loss of water (hence its
naturally occurring polyamides
are proteins, such as wool and silk. name). It can also be prepared by
Artificially made polyamides can ring-opening polymerization
be made through step-growth of lactide, the cyclic dimer of the
polymerization or solid-phase basic repeating unit.
synthesis yielding materials such
as nylons, aramids, and sodium
poly(aspartate). Synthetic
polyamides are commonly used in
textiles, automotive industry,
carpets, kitchen utensils and
sportswear due to their high
durability and strength.
 https://www.treehugger.c
https://www.weyer- om/pros-cons-corn-based-
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plastic-flexible-tubingconduit-
corrugated-pa12-polyamide-tube-
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 METHODS, PROCESSES, AND EQUIPMENT
FOR PLASTIC & RUBBER MANUFACTURING
 Types of Plastics
o Thermoplastics Common Types
5. Polycarbonate (PC) – are a group 6.
of thermoplastic polymers
containing carbonate groups in
their chemical structures.
Polycarbonates used in
engineering are
strong, tough materials, and some
grades are optically transparent.
They are easily worked, molded,
and thermoformed.
Polyether ether ketone (PEEK) -is a
colorless organic thermoplastic polym
er in the polyaryletherketone(PAEK)
family, used in engineering
applications. PEEK is a
semicrystalline thermoplastic with
excellent mechanical and chemical
resistance properties that are
retained to high temperatures
 https://matmatch.com/learn/material
/polyether-ether-ketone-peek

https://aussiesworld.wordpress.com/2019/02/09/5-
things-to-remember-when-buying-polycarbonate-
plastic-sheets/
 METHODS, PROCESSES, AND EQUIPMENT
FOR PLASTIC & RUBBER MANUFACTURING
 Types of Plastics
o Thermoplastics Common Types
7. Polyethylene (PE) – is the most
common plastic in use today. It is a
polymer, primarily used
for packaging (plastic bags, plastic
films, geomembranes, containers
including bottles, etc.)
8. Polypropylene (PP)- it is belongs to
the group of polyolefins and
is partially crystalline and non-polar.
Its properties are similar
to polyethylene, but it is slightly harder
and more heat resistant. It is a white,
mechanically rugged material and
has a high chemical resistance
https://www.creative
mechanisms.com/blo
https://totebagfactory.com
g/polyethylene-pe-
/blogs/news/common-uses-
for-prototypes-3d-
of-polypropylene
printing-and-cnc
 METHODS, PROCESSES, AND EQUIPMENT
FOR PLASTIC & RUBBER MANUFACTURING
 Types of Plastics
o Thermoplastics Common Types
9. Polyvinyl chloride (PVC) - is the
world's third-most widely
produced
synthetic plastic polymer (after
polyethylene and polypropylen
e. PVC comes in two basic
forms: rigid (sometimes
abbreviated as RPVC) and
flexible. The rigid form of PVC is
used in construction for pipe
and in profile applications such
as doors and windows. It can
be made softer and more
flexible by the addition
of plasticizers, the most widely
used being phthalates.
8. Polycarbonate (PC)-are a group
of thermoplastic polymers
containing carbonate groups in their
chemical structures. Polycarbonates
used in engineering are
strong, tough materials, and some
grades are optically transparent.
Polycarbonate is a durable material.
Although it has high impact-
resistance, it has low scratch-
resistance. Therefore, a hard coating
is applied to
polycarbonate eyewear lenses and
polycarbonate exterior automotive
components.
 https://www.excelitepla
s.com/polycarbonate-
sheet-bible/

https://omnexus.specialchem.com/sele
ction-guide/polyvinyl-chloride-pvc-
plastic

https://www.calsak
.com/polymers-
additives/polycarb
onate/
 METHODS, PROCESSES, AND EQUIPMENT
FOR PLASTIC & RUBBER MANUFACTURING
 Types of Plastics
o Thermoplastics Common Types
11. Polystyrene (PS)-is a
8.
synthetic aromatic hydrocarbon p
olymer made from
the monomer known as styrene.
Polystyrene can be solid or
foamed. It is a rather poor barrier
to oxygen and water vapor and
has a relatively low melting point
Polyoxymethylene (POM)-is an
engineering thermoplastic used in
precision parts requiring high
stiffness, low friction, and excellent
dimensional stability. Typical
applications for injection-molded
POM include high-performance
engineering components such as
small gear wheels, eyeglass
frames, ball bearings, ski bindings,
fasteners, guns, knife handles, and
lock systems. The material is widely
used in the automotive
and consumer electronics industry
 http://3m- https://ww
dubai.com w.rdiplastics
/polystyren .com/en/n
e/ ews/que-
es-el-pom/

https://www.cr
aftechind.com
/hompolymer-
https://dienami plastic-
cs.com.au/blog materials-
/let-talk-about- close-
polystyrene/ polyoxymethyl
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 METHODS, PROCESSES, AND EQUIPMENT
FOR PLASTIC & RUBBER MANUFACTURING
 Types of Plastics
o Thermosetting Common Types
1. Cyanate ester - are chemical 2. Epoxy -refers to any of the basic
substances in which components or cured end
the hydrogen atom of the
phenolic OH group is substituted products of epoxy resins, as well
by a cyanide group. Cyanate as a colloquial name for
esters based on a bisphenol or the epoxide functional group.
novolac derivative are used in Epoxy resins, also known
the production of resins.
Cyanate esters can as polyepoxides, are a class of
be cured and post cured by reactive prepolymers and polym
heating, either alone at ers which contain epoxide
elevated temperatures or at groups
lower temperatures in presence
of a suitable catalyst.
https://www.openpr
.com/news/1957243
https://www.amazon
/new-report-
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explores-hottest-
Mannol-Epoxy-
trends-in-cyanate-
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ester-resin-market
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O
 METHODS, PROCESSES, AND EQUIPMENT
FOR PLASTIC & RUBBER MANUFACTURING
 Types of Plastics
o Thermosetting Common Types
3. Polyurethane - is 2. Silicone - is a polymer made up
a polymer composed of siloxane. They are typically
of organic units joined colorless, oils or rubber-like
by carbamate (urethane) links. substances. Silicones are used in
While most polyurethanes
are thermosetting polymers that sealants, adhesives, lubricants,
do not melt when heated. medicine, cooking utensils, and
Polyurethanes are used in the thermal and electrical insulation.
manufacture of high-resilience
foam seating, rigid foam
insulation panels, microcellular
foam seals and gaskets, spray
foam, durable elastomeric
wheels and tires.
https://en.wikipedia.o https://www.healthli
rg/wiki/Polyurethane ne.com/health/body
-modification/is-
silicone-toxic
 METHODS, PROCESSES, AND EQUIPMENT
FOR PLASTIC & RUBBER MANUFACTURING
 Types of Plastics
o Thermosetting Common Types
3. Vulcanized rubber - is an
example of type
of rubber polymer. A substance
which has a molecular structure
built completely from a large
number of similar units bonded
together known as polymers.
Polymers has high molecular https://blog.ansi.org/2019
mass. They are also called /12/iso-2921-2019-
macromolecules. vulcanized-rubber-
temperature/#gref
 METHODS, PROCESSES, AND EQUIPMENT
FOR PLASTIC & RUBBER MANUFACTURING
 Types of Manufacturing
Processes
➢ 3D Printing - create three-
dimensional parts directly
from CAD models by
building material layer by
layer until a complete
physical part is formed.
As 3D printers require no
tooling and minimal
setup time for a new
design, the cost of
producing a custom part
is negligible in
comparison with
traditional manufacturing
processes.
Manufacturing Process
1.Print setup: Print preparation software is used for
orienting and laying out models within a printer’s
build volume, adding support structures (if
needed), and slicing the supported model into
layers.
2.Printing: The printing process depends on
the type of 3D printing technology: fused
deposition modeling (FDM) melts a plastic
filament, stereolithography (SLA) cures liquid resin,
and selective laser sintering (SLS) fuses powdered
plastic.
3.Post-processing: When printing is complete,
parts are removed from the printer, cleaned or
washed, post-cured (depending on the
technology), and the support structures removed
(if applicable).
 METHODS, PROCESSES, AND EQUIPMENT
FOR PLASTIC & RUBBER MANUFACTURING
 Types of Manufacturing Processes
➢ CNC Machining - includes mills,
lathes, and other computer-
controlled subtractive
processes. These processes start
with solid blocks, bars, or rods of
metal, or plastic that are shaped
by removing material through
cutting, boring, drilling, and
grinding.
Unlike most other plastic
manufacturing processes,
CNC machining is a
subtractive process where
material is removed by either a
spinning tool and fixed part
(milling) or a spinning part with
a fixed tool (lathe).
Manufacturing Process
1. Job setup: CNC machines require an
intermediary step of generating and validating
toolpaths (CAD to CAM). Toolpaths control
where the cutting tools move, at what speeds,
and any tool changeovers.
2. Machining: The toolpaths are sent to the
machine where the given subtractive process
begins. Depending on the desired shape of the
final product, the workpiece may need to be
set in a new position so that the tool head can
reach new areas.
3. Post-processing: After manufacture, the part
is cleaned and deburred, trimmed.
 METHODS, PROCESSES, AND EQUIPMENT
FOR PLASTIC & RUBBER MANUFACTURING
 Types of Manufacturing
Processes Manufacturing Process
1.Mold preparation: The mold is coated with a
➢ Polymer Casting- a reactive release agent to facilitate demolding, and
liquid resin or rubber fills a mold often preheated to a material specific
which reacts chemically and temperature.
solidifies. Typical polymers for 2.Casting: The synthetic resin is mixed with a
casting include polyurethane, curing agent and poured or injected into the
epoxy, silicone, and acrylic. mold, where it fills the mold cavity.
Polymer casting is relatively 3.Cure: The casting cures in the mold until it
inexpensive, with little initial solidifies (subjecting the mold to heat can
investment, but thermoset accelerate the cure time for certain polymers).
polymers for casting are usually 4.De-mold: The mold is opened and the cured
more expensive than their part is removed.
thermoplastic counterparts and 5.Trimming: Casting artifacts like flash, sprues,
molding cast parts is labor- and seams are cut or sanded away.
intensive
 METHODS, PROCESSES, AND EQUIPMENT
FOR PLASTIC & RUBBER MANUFACTURING
 Types of Manufacturing
Processes Manufacturing Process
1.Charging: Plastic powder is loaded into the
➢ Rotational molding - also called mold cavity, and then the remaining parts of
rotomolding is a process that the mold are installed, closing the cavity for
involves heating a hollow mold heating.
filled with powdered 2.Heating: The mold is heated until the plastic
thermoplastic and rotated powder melts and adheres to the mold’s walls,
around two axes to produce while the mold is rotated along two
mainly large hollow objects. perpendicular axes to ensure a uniform plastic
Processes for rotomolding coating.
thermoset plastics are available 3.Cooling: The mold is slowly cooled while the
as well, however less common. mold remains in motion to ensure that the skin
of the part does not sag or collapse before fully
solidifying.
4.Part removal: The part is separated from the
mold, any flashing is trimmed away.
 METHODS, PROCESSES, AND EQUIPMENT
FOR PLASTIC & RUBBER MANUFACTURING
 Types of Manufacturing Manufacturing Process
Processes 1.Clamping: A plastic sheet is clamped in a frame.
2.Heating: The sheet and the frame are moved close
➢ Vacuum forming -is a to heating elements, which makes the plastic soft
manufacturing method where a and pliable.
plastic is heated and formed, 3.Vacuum: The frame is lowered, and the plastic is
typically using a mold. Vacuum stretched over the mold, while vacuum is activated
forming machines vary in size to suck all the air out from between the plastic and
the mold, thus forming the part.
and complexity from low-cost
4.Cooling and release: Once the part has been
desktop devices to automated formed over the mold, it must be given time to cool
industrial machinery. Commonly before removal. Cooling system like fans and
vacuum formed parts include sprayed mist are sometimes used to reduce cycle
product packaging, shower times.
trays, car door liners, boat hulls, 5.Trimming: Once the part is released, excess
and custom products like dental material is cut off either by hand or with a CNC
aligners. machine.
 METHODS, PROCESSES, AND EQUIPMENT
FOR PLASTIC & RUBBER MANUFACTURING
 Types of Manufacturing Manufacturing Process
Processes 1.Mold setup: If the part has inserts, these are
➢ Injection Molding -Injection added either by hand or robotically. The mold is
molding (IM) works by injecting closed by a hydraulic press.
molten thermoplastic into a 2.Plastic extrusion: Small plastic pellets are
mold. It is the most widely used melted and extruded through a heated
process for mass manufacturing chamber by a screw.
of plastic parts. Despite the high 3.Molding: The molten plastic is injected into the
initial costs and slow ramp up, mold.
injection molding has no match
4.Cooling and release: The part cools in the
for high volume applications.
Once the tooling is up and mold until it is solid enough to be ejected, either
running, cycle times only take a mechanically or by compressed air.
few seconds, and millions of 5.Post-processing: Sprues, runners and any flash
high-quality parts can be (if applicable) is removed from the part, often
produced at a fraction of the automatically as part of the mold opening.
cost of all other manufacturing
processes.
 METHODS, PROCESSES, AND EQUIPMENT
FOR PLASTIC & RUBBER MANUFACTURING
 Types of Manufacturing Manufacturing Process
Processes 1.Plastic extrusion: Plastic is heated and pushed
➢ Extrusion molding - are works by through a heated chamber by a screw.
pushing plastic through a die. 2.Molding: Plastic is forced through a die that
The shape of the die is a cross- creates the final shape of the part.
section of the final part. Extrusion 3.Cooling: The extruded plastic is cooled.
machinery is relatively cheap 4.Cut or spool: The continuous shape is spooled
compared to other industrial or cut into lengths.
machines like CNC or injection
molding as it is less complex and
does not require such high levels
of machine accuracy. Due to
the simple shapes, dies are also
less expensive, with tooling costs
that are a fraction of molds for
injection molding.
 METHODS, PROCESSES, AND EQUIPMENT
FOR PLASTIC & RUBBER MANUFACTURING
 Types of Manufacturing Manufacturing Process
Processes 1.Mold setup: Small plastic pellets are melted
➢ Blow molding - is a and formed into a hollow tube, called the
manufacturing technique used parison or preform (depending on the blow
to create hollow plastic parts by molding subtype).
inflating a heated plastic tube 2.Molding: The parison is clamped into a mold
inside a mold until it forms into and gets inflated by pressurized air until it takes
the desired shape. Blow molding the shape of the inside of the mold.
is the most common process for 3.Cooling and release: The part cools in the
creating hollow plastic products mold until it is solid enough to be ejected.
at scale. Typical applications
include as bottles, toys,
automotive components,
industrial parts, and packaging.
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Reference:
https://formlabs.com/asia/blog/guide-to-manufacturing-processes-for-
plastics/#:~:text=in%20your%20browser.-
,Manufacturing%20Process,spooled%20or%20cut%20into%20lengths.