UNIVERSITI KUALA LUMPUR

MALAYSIAN SPANISH INSTITUTE

TECHNICAL
REPORT

SUBJECT CODE : SDB24103

SUBJECT TITLE : DESIGN FOR PLASTIC AND ELASTOMER

DURATION :

STUDENT NAME WAN MUHAMMAD AQIL BIN WAN MOHD ZAINUDIN

STUDENT ID NO 54213122038

PROGRAM BETA MANUFACTURING

SEMESTER SEMESTER 1
INTRODUCTION

Plastics are non-metallic compounds that are produced synthetically. It can be

formed into many different shapes and hardened for industrial use. Products
made of plastic moulding are ubiquitous. Examples include containers, safety
caps, tubes made of plastic, grips, toys, bottles, cases, accessories, kitchen
utensils, and many more. You even use a keyboard and a mouse that are
made of plastic through moulding. This method of creation is used to make
even the plastic components of the chair you are sitting on. Inserting molten
liquid plastic into a pre-formed mould, like a bottle mould, is the fundamental
principle of plastic moulding. The mould will then be taken off to reveal the
plastic bottle after it has had time to cool. Garden pots, cabinets, office trays
and boxes, barriers, barricades, traffic signage, and displays for product and
marketing promotions are just a few of the many plastic products that can be
custom-molded by plastic moulding. You should first be familiar with the
various procedures if you intend to start a plastic moulding business. Select a
plastic moulding technique that works with your resources, knowledge, and
budget.
1.0 BLOW MOLDING

Blow forming, also referred to as blow moulding. is a manufacturing process that creates
hollow plastic parts that are used to make smaller hollow products, like plastic bottles,
such as blow-molded products. A variety of thermoplastic materials, including
polypropylene (PP), polyethylene terephthalate (PET), polyvinyl chloride (PVC), low
density polyethylene (LDPE), and high density polyethylene, can be used to create blow
moulded parts (HDPE). Thermoplastic materials can frequently be used in a wide range
of applications without requiring significant material or component modification.

The majority of blow-molded plastic components are used in bottles, but the industry also
creates items for the fields of aircraft, automobiles, building and construction, electronics,
furniture, lawn and gardens, medicine, and recreation. Balls, toys, bellows, and car
bumpers are some examples of applications (fenders). Many bottles and jars, like plastic
containers for salt and sauces, are used in the food industry to package both solid and
liquid goods. Most food packaging containers are blow moulded.

Hollow plastic parts can be formed and joined together using the blow moulding
manufacturing process. Glass bottles and other hollow shapes can also be formed using
this technique. Extrusion blow moulding, injection blow moulding, and injection stretch
blow moulding are the three primary types of blow moulding.

Imagine a plastic inflatable tube that is closed on both ends except for one point to get a
sense of the blow moulding procedure. The tube will expand if air is introduced at this
point, thinning the tube walls. Like blowing up a balloon, that is how it feels.

A parison or preform, a hot, malleable plastic tube, is used to start the blow moulding
process. The sandwich is sandwiched between two mould halves that each have one or
more hollow cavities. Next, clamps are used to join the mould halves. A hollow plastic
part in the shape of the cavity is created by blowing air into the cavity and expanding it
against the interior walls of the mould. The hot plastic cools by coming into contact with
the cooled mould, which is typically filled with water. The mould opens and the part is
ejected after the part has cooled.
Image product use blow molding
1.1 EXTRUSION BLOW MOLDING

The extrusion blow moulding (EBM) process begins with the melting and plasticization
of the raw material in the barrel and then extruded using a traditional downward tube
from the extruder's head. A section of the tube embryo is stopped when the tube
parison reaches a specific length and put into the blow mould while still hot. The mould
is closed by pinching the bottom end shut and catching and holding the neck end open.
Through the air blowing nozzle, compressed air was blown into the pair. The mould
cavity's desired shape will be precisely inflated into the tube prison. The mould can be
opened to remove the product once it has completely cooled.

The most popular blow moulding technique is extrusion, which is used to create items
like milk bottles, shampoo bottles, automotive ducting, watering cans, and other
industrial parts. The ability to create complex geometries as well as the methods quick
and low-cost production rates are its main benefits. The material's low strength and the
simple production of hollow parts are some of its drawbacks. Spin trimming is necessary
when creating wide-neck bottles.
1.2 INJECTION BLOW MOLDING

Injection blow moulding (IBM) is the process where the material is melted and forced
(injected) into a precisely sized die until it cools and solidifies into the desired product
shape. Three steps make up the process: injection, blowing, and ejection.

Bottles, jars, and other containers are typically produced in large quantities using
injection blow moulding. Due to production rate restrictions, this method is less popular
and is best used for small products, like those used in medical applications. The ability
to accurately produce intricately moulded necks is its main benefit. However, it is limited
to the production of small bottles, and the barrier's strength is weak.

A barrel and screw assembly known as an extruder is the foundation of the injection
blow moulding machine and it melts the polymer. The molten polymer is injected
through nozzles into a heated cavity and core pin after being fed into a hot runner
manifold. The preforms internal shape is created by a core rod that is clamped around
the cavity mould, which creates the external shape. The preform is made up of a fully
formed bottle or jar neck and a substantial polymer tube that will serve as the body.
Similar to a test tube with a threaded neck in appearance.

The hollow, chilled blow mould is opened, and the core rod is rotated and clamped
inside. The core rod's open end allows compressed air to enter the preform, inflating it
to the shape of the finished product.

The blow mould opens and the core rod is rotated to the ejection position following a
cooling period. The finished product is removed from the core rod and, if desired, is
leak-tested before being packaged. The number of cavities in the preform and blow
mould can range from three to sixteen, depending on the size of the article and the
output required. Three different sets of core rods enable simultaneous preform injection,
blow moulding, and ejection.
1.3 STRECH BLOW MOLDING

The parison is created in stretch blow moulding (SBD) in a manner similar to that of injection
blow moulding, with the exception that after being transferred to the blow mould, it is heated and
stretched downward by the core prior to inflation. Utilizing the material's increased strength is
possible with the stretching technique.

Stretch moulding is very useful for low volumes and for allowing the mould wall to be shaped in
non-round and rectangular shapes. However, the technique has limitations on bottle designs. It
is used to create components with high durability requirements or those subject to internal
pressures, like soda bottles.

1.4 ADVANTAGE BLOW MOLDING

 Well suited to low and high production rates.

 Quick product revisions for increased flexibility.

 Tooling is less expensive than other molding.

 Each part price is less than Rotational Molding.

 Trim and flash reusable into finished parts .

1.5 DISADVANTAGE BLOW MOLDING

 Environmental Disadvantages effecting.

 Process and Material Limitations.

 Inability to produce bottles with calibrated neck finishes

  Machines typically dedicated to a narrow range of sizes

 Trimming required

1.6 BLOW MOLDING APPLICATIONS

 Milk bottles

 Pharmaceutical bottles

 Antifreeze bottles

 Polypropylene bottles

 Coliseum seats

 One-piece chair

 Ice chests and coolers

 Double-wall player case

 Garbage cans

 Drums

 Fuel tanks
2.0 TRANSFER MOLDING

The transfer moulding process is the most popular method for encasing integrated
circuits in virtually all plastic packages. The process of making components in a closed
mould using a thermosetting material is known as transfer moulding. The material is
pushed through runners and gates into the closed cavity or cavities under pressure and
in a hot, plastic state from an auxiliary chamber known as the transfer pot.

Casting material is pressed into a mould during the manufacturing process known as
transfer moulding. Transfer moulding has higher dimensional tolerances and a lower
environmental impact than compression moulding, which has an open mould to the fill
plunger. More pressure is placed on the mould cavity during transfer moulding than
during injection moulding. As a result, thicker reinforcing fibre matrices can have higher
resin saturation levels. In contrast to injection moulding, the transfer mould casting
material may also start the process as a solid. This may result in less expensive
equipment being required and time savings. It's possible that an equivalent injection
moulding process would fill parts faster than a transfer process.

2.1 THE TRANSFER MOLDING PROCESS

Transfer moulding requires that a predetermined quantity of a cold material be

transferred into a heated mould that is designed to produce a customer's part in order
for it to function. The part is then released, and any excess material is removed from the
geometry.

An uncured piece of pre-catalyzed rubber is first added by workers to a pot that is

placed atop a mould. When the mould closes under the force of a moulding press, a
small hole is made in the material, forcing it into the cavity where it is forced into the
shape of the final product. While the rubber cures, the moulding press keeps it closed.
Depending on how quickly the material in the mould cures, this process takes a certain
amount of time, which is frequently only a few minutes.

Workers take out the transfer pad material, open the mould, take out the plunger that
was used to inject the material, and after the part has dried out and solidified, they take
it out of the cavity of the mould. They frequently remove any flash and extra material
from the end piece at the moulding press during the subsequent moulding cycle.
2.2 ADVANTAGE OF TRANSFER MOLDING

 Reducing flash along mould parting lines.

 Speedy setup. This is particularly true if there are many moulds or mould cavities
being used.
 Low cost of maintenance.
 Tools typically cost less than other process alternatives.
 The capacity to insert metal into rubber parts. Workers can alternate heated
rubber and metal or other materials in layers during some transfer moulding
processes to produce specialised insert moulded parts.
 Design adaptability Customers can include numerous complex features in the
parts they design for this process.
 It is possible to create unique material blends.
 Stability in dimensions.
 consistent part thickness
 It is feasible to produce large quantities.

2.3 DISADVANTAGE OF TRANSFER MOLDING

 Material usage. In order to complete the procedure, the transfer pad and sprues,
which are channels through which uncured rubber or other charges are
transferred to the mould cavity, are taken out and discarded. This substance is
not recyclable.
 Rivalry with injection moulding For a higher initial investment, injection moulding
can typically produce a faster cycle than transfer moulding, making it more
appropriate for some applications.
 Some part designs that result in flaws in the finished product can make it difficult
for the material to move around in the mould.
 Compared to other processes, transfer moulding is labor-intensive and thus can
be expensive for parts.
2.4 MATERIALS

A thermoset polymer is the substance that is most frequently used for transfer moulding.
This kind of polymer is simple to work with and mould, but it takes on a permanent
shape after curing. The component for straightforward homogeneous transfer moulded
parts is made solely of this plastic substrate. In contrast, resin transfer moulding
enables the creation of composite materials by first inserting a fiber into the mould and
then injecting a thermosetting polymer into it.

Transfer moulding can result in defects such as voids and dry resin (in the case of resin
transfer moulding), which are frequently made worse by high viscosity materials. This is
so that air pockets won't be left behind when a high viscosity plastic flows through a thin
mould and misses entire vacated areas. A "dry" area is created when air pockets
remain near fibers; this prevents load from passing through the fibers in the dry area.

Polyurethanes or epoxy resins are frequently used as plastic-making materials. Before

curing, both of these are malleable and soft; once set, they are much harder. Many
different types of useful materials can be used for transfer moulding, such as:

 Silicone
 Conductive rubber material
 FKM and other fluorocarbon rubbers.
 Neoprene
 EPDM
 Butyl
 SBR
 Polyisoprene
 Nitrile rubber
 Custom rubber compounds.
 Kevlar fibers
 Organic fibers
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