Composites
Applications Guide
COMPRESSION MOLDING: Molding Processes and Equipment
Part Six, Chapter IV
Copyright 2008
In This Chapter
1. Introduction
2. Charging
3. Part Formation
4. Finishing
1. INTRODUCTION—As stated earlier, compression
molding involves pressing and curing a premanufactured
compound in a closed mold cavity under pressure and
often heat.
The compression molding process involves four steps.
First, the compound is inserted or charged into the mold.
Second, the mold closes and the part is formed. Third,
the part is allowed to cure. Fourth, the formed-and-cured
part is removed from the mold and finished. One to two
operators per press are generally sufficient even for
rapid cycle times. Additional operators may be required
for very large parts. Operators can work on charge
preparation for the next part or part finishing of the last
part during molding.
2. CHARGING—Charging (or placing) of the material
to the mold varies based on compound form.
A. SMC—The charge must be prepared by
removing the carrier film from the sheet and cutting
the sheet to the desired shape. Cutting can be done
manually or by computer-controlled slitting. Two
major factors influence the configuration of the
charge:
1) First, the charge must contain enough
material to fill the volume of the closed mold.
Since, in most cases, it is impractical to
measure volume, the amount of charge
added to the mold is controlled by weight.
The standard charge weight for a specific
compound and mold are often determined
experimentally. Depending on part size and
the areal weight of the SMC, several layers
of SMC may be needed to achieve the
required weight.
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2) Second, the surface area of the charge must
be sufficient so that the material has time to
flow and fill the mold prior to gelation. As the
surface area of the charge increases, the
chance of trapping porosity in the molded
parts also increases. Flow of the material in
the mold helps to remove air from
compound. Complex parts may require that
several separate charges be placed
throughout the mold to ensure complete fill.
One drawback to multiple charges is that
knit lines are created when the material
flows and the charges meet. Knit lines are
often low in strength and are susceptible to
cracking. The shape and surface area of the
charge are again generally determined
experimentally for a specific compound and
mold combination. The surface area of the
charge is generally referred to as a
percentage of the mold surface area or mold
coverage.
After the charge is prepared, it may be loaded into the
mold manually or with automatic loading equipment.
B. BMC—Three basic methods are used for
charging BMC to the mold:
1) Hand charge placement is similar to
charging of SMC in that the charges are
controlled by weight. After weighing, the
charge is placed in predetermined areas of
the mold.
2) Transfer involves the use of a plunger to
force material into the mold.
3) Injection involves use of a screw extruder to
push material into the mold. For transfer and
injection molding, pressure applied to the
mold serves to hold the mold together during
the compound charging rather than to
compress the material into the mold.
Transfer and injection compound charging processes
have shorter cycle times and require less labor than
hand charging, but also require more capital expense.
COMPRESSION MOLDING: Molding Processes and Equipment
Copyright 2008
BMC continued:
For wet molding, a fiber preform is placed in the mold
and the compound paste is poured into the mold over
the preform. The pressure applied to the mold during
closing forces the paste to flow into the preform, wetting
the glass fiber.
3. PART FORMATION—Compression molding is done
using a matched-die tool. A schematic of a simple
compression molding tool is shown below:
Figure 6/IV.1 - Compression molding tool schematic.
A. The tool consists of a cavity and a plug or
plunger. Guide pins maintain the proper relation
between the tool members. The tool cavity forms the
outer surface of the part. The tool plunger forms the
inner surface of the part being molded and serves to
compress the compound when the tool is closed.
The molding compound is thus confined to the open
space between the plunger and cavity while it cures.
Numerous features can be incorporated into the
molds to facilitate production.
B. Elevated temperature molding requires
provision for heating in the mold design. Some
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presses are equipped with heating platens that
transfer heat to the molds. In some mold designs,
the cavity and plunger are drilled to permit a heating
medium to circulate for heating. Common heating
mediums are oil or steam. A boiler or hot oil heater is
required to heat the steam or oil and circulate it
between the mold and heating unit. Knockout or
ejector pins are often used to push the molded part
away from the mold.
C. Conventional compression molds are made
from P20 tool steel and are usually chrome-plated.
Alternate tool materials such as aluminum, nickel
shell and composite can be used for low-pressure
compression molding. Tools made from these
alternate materials are less expensive than tools
made from tool steel; however, the production run
life of tools made from these alternate materials are
generally shorter than for tool steel.
D. Compression molding is done in hydraulic,
air, or mechanically operated presses with hydraulic
being the most common. A photograph of a
hydraulic press is shown on this page. The two
general types of hydraulic presses are downstroke
and upstroke presses:
1) The downstroke press makes use of an
overhead cylinder to move the top platen
downward and apply pressure to the mold.
This type of press is advantageous for
molding large parts since the lower platen
remains at a constant level and allows the
operator to walk around the mold and on the
platen as is sometimes required for charging
or demolding large parts.
2) An upstroke press has the cylinder
positioned below, and the ram moves the
lower platen upward. This type of press
provides greater safety for the operator. A
malfunction in the hydraulic circuit causes
the lower platen to drift downward, opening
the press. A hydraulic malfunction in a
downstroke press could cause an operator
to be trapped. The hydraulic press shown in
the photograph in Figure 6/IV.2 is a
downstroke press.
E. Molds are generally bolted to press platens
with clamp bolts at the front and back. Sheets of
 COMPRESSION MOLDING: Molding Processes and Equipment
Copyright 2008

phenolic or glass-bonded mica are often used to the part the lower the pressure that can be exerted.
insulate the mold from the press platen. Use of More complex parts require high molding pressures
insulation reduces the heat transferred from the to ensure complete fill. Molding temperature and
mold to the press and gives better thermal uniformity time are influenced by compound flow and cure
within the mold. characteristics and by part size and thickness.
F. Mold daylight is the measurement between the 4. FINISHING—Finishing of the part involves flash
upper and lower platens of the press in the open removal, drilling of any holes required for assembly, and
position. This dimension minus the stroke (the packaging. Flash removal can be accomplished with
maximum platen movement) is the minimum die sandpaper, a file or a box knife.
height to ensure that pressure will be applied to the
part. The opening between mold halves must be
sufficient to allow charging and part removal.
G. Press controls generally include pressure
controls, closing and opening speed controls and a
clamp timer. When the clamp time expires, the press
automatically opens. Safety features, such as laser
systems that prevent the press from closing if an
operator is too close to the press, can also be
incorporated.
H. Molding conditions vary between the different
compound forms. Typical molding conditions are
shown in the table below:

Compound Pressure Temperature Time

Forms

SMC
Conventional 500-3000 270-320°F (132- 30
psi 160ºC) seconds
Low 180-220°F (82- to 5
Pressure/Low 50-500 psi 104ºC) minutes
Temperature

BMC
Conventional 500-3000 270-320°F (132- 30
psi 160ºC) seconds
Low 180-220°F (82- to 5
Pressure/Low 50-500 psi 104ºC) minutes
Temperature

Wet Molding <50 psi Room 2 to 10

Compound temperature to minutes
350°F (177ºC)

I. Molding pressure is influenced by compound

flow characteristics, press tonnage and part
complexity. On a particular tonnage press, the larger

Cook Composites & Polymers

P.O. Box 419389 Kansas City, MO 64141-6389
Ph: (816) 391-6000 Fax: (816) 391-6125
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COMPRESSION MOLDING: Molding Processes and Equipment
Copyright 2008

Cook Composites & Polymers

P.O. Box 419389 Kansas City, MO 64141-6389
Ph: (816) 391-6000 Fax: (816) 391-6125
www.ccponline.com
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 COOK COMPOSITES AND POLYMERS CO.

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P.O. Box 419389 Kansas City, MO 64141-6389
Ph: (816) 391-6000 Fax: (816) 391-6125
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