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Thermoplastics
Thermoplastics soften when heated and
can be moulded into required shapes
when in this state. They will harden again
on cooling. By heating and cooling, they
can be softened and heated over and
over again.
Thermosetting plastics
Thermosetting plastics undergo a
chemical change during moulding and
hardening and, therefore, cannot be
softened again by heating.
The structure of plastics
The main raw material for plastics is crude
oil. The chemicals required are obtained by
refining the crude oil. These chemicals are
made from molecules containing a no. of
atoms. These small molecules called
monomers, react together to form long
chain molecules. The chemical process of
linking the small molecules together is
called polymerisation. The product of
polymerisation is called a polymer.
Plastic additives
Pigment – gives colour
Stabilisers – prevent degradation
Lubricants – makes moulding easier
Fillers – add strength to plastic eg wood
flour, glass fibre, cotton, etc.
Plasticiser – increases flexibility.
Polymer structure
The molecular structure of plastics can be;
Linear chain,
Branch chain,
Cross-links.
Linear and Branch Chain
A – split mould
B – heater
C – hopper
D – hydraulic
ram
E – torpedo
(spreader)
Injection moulding produces accurate and
complex products with high quality finish.
Production is fast with little waste.
Wide range of products including bowls,
buckets, containers, toys, electrical parts
and car parts.
Injection moulded parts can be
recognised by the distinctive circular
marks (5-10mm) caused by pins used to
remove object from it’s mould.
Blow Moulding
Used to make bottles and hollow toys.
Air is blown into a plastic tube, called a parison,
to take the shape of the mould.
PVC and polythene are often used.
Blow moulding
Compression Moulding
Thermoset plastics are shaped with heat and
pressure causing cross-linking.
The polymer can be in powder or slug (cube)
form.
Products such as electrical fittings, saucepan
handles and bottle tops are often formed out
of formaldehyde plastics.
High quality finishes are achieved with only
the removal of ‘flash’ (excess material usually
at the mould split) for finished products.
Transfer Moulding
Thermoset polymers can be formed when a preset
amount of material is placed in a separate cavity
and heated. A plunger moves the material into the
shaped mould with high pressure.
Rotational Moulding
A measured amount of polymer is placed in a
shaped mould cavity.
The mould is closed and rotated until the
polymer lines the mould and is then opened.
Plastic footballs are produced in this way.
Rotational moulding
Vacuum Forming
Plastic sheet is clamped and heated.
Heat is removed and pattern raised.
Vacuum forces the sheet onto the pattern.
The sheet is removed and trimmed.