TRANSFER AND COMPRESSION

MOULDING

By,
JAYAVARSHINI.E
KAVITHA.D
KALPANA.C
KARTHIKEYAN
KARTHICK
 MOULDING
 Moulding is a process of manufacturing by
shaping liquid or pilable raw material using a
rigid frame called Mold or Matrix.
 COMPRESSION MOULDING
Compression molding process is one of the
lowercost molding methods as compared to
injection molding and transfer molding. It is
a high pressure forming process in which the
molten plastic material is squeezed directly
into a mould cavity by the application of
heat and pressure to conform to the shape of
the mold.
FACTORS TO BE CONSIDERED BEFORE
COMPRESSION MOULDING
 Amount of plastic material(charge).
 Heating time and melting temperature of
plastic material.
 Cooling time.
 Pressure required to squeeze the material
into the mold cavity.
TYPES OF COMPRESSION MOLDING COMPOUNDS

Two types of molding compounds :

1. Bulk molding compounds.
2. Sheet molding compounds.
 In bulk molding compound, the plastic
material are blended with fillers and short
fibres and placed in the mold cavity.
 In sheet molding compounds,the long fibre
sheet is usually cut according to the mold
cavity and placed into the mold surface.The
resin is placed on the fibre sheet .
 It is a layer by layer making process.The
process is completed until desired thickness
is obtained.
 The long fiber sheet results in better
mechanical properties as compared with the
bulk molding compound products.
 In both the molding compounds (BMC,SMC)
the plastic materials are conformed to the
mold cavity,with the application of heat and
pressure.
MATERIALS USED:
 Different types of thermosets and
thermoplastics materials can be used for
compression molding
 process. For example: Epoxies, Urea
formaldehyde (UF), Melamine formaldehyde
(MF),
 Phenolics (PF), Polyester, Polyamide (PI),
Polyamide-imide (PAI), Polyphenylene sulfide
(PPS),
 Polyetheretherketone (PEEK), Torlon, and
Vespel.
APPLICATIONS:
 Compression molding process is used for
manufacturing electrical and electronic
equipments ,brush and mirror handles, trays,
cookware knobs, clothes dryer blower fan blade,
cooking utensils, milling machine adjustment
wheel, water testing equipment buttons,
dinnerware, appliance housings, aircraft main
power terminal housing, pot handles, dinnerware
plates, automotive parts (such as hoods, fenders,
scoops, spoilers, gears), flatware, buttons,
buckles, and large container. Compression molding
is also suitable for heavy molding applications.
TRANSFER MOLDING
In the transfer molding, polymer charge is
transferred from the transfer pot to the
mold.The mold is cooled and molded part is
ejected.
 Transfer molding process combines the
principle of compression and transfer of the
polymer charge.
PROCESS OF TRANSFER
MOLDING
 The mold interior surfaces may be gel coated.
Fiber content of a transfer molded composite
can be as high as 60% volume. The fill material
may be a preheated solid or a liquid. It is
loaded a chamber known as a pot.
 A plunger forces material from the pot into
the heated mold cavity. If feed stock is
initially solid , the forcing pressure and mold
temperature melt it.Standard mold features
such as sprue channels gate flow and ejector
pins are used.The heated mold ensures that
the flow remains liquid for complete filling
 Once filled the mold can be cooled at a
controlled rate for optimal thermoset curing.
 Transfer molding is a manufacturing process
where the casting material is forced into the
mold.
 It results in higher dimensional tolerances and
less environmental impact.It uses higher
pressure to uniformly fill the mold cavity
compared to injection molding.
 The transfer mold casting material may start
the process as a solid.This can reduce
equipment costs and time dependency
PROCESS PARAMETERS

 Heating time
 Melting temperature of the charge
 Applied pressure
 Cooling time
TYPES OF TRANSFER MOLDING
 Resin transfer molding.
 Vacuum transfer molding.
 Micro transfer molding.
RESIN TRANSFER MOLDING
VACUUM TRANSFER MOLDING
MICRO TRANSFER MOLDING
MATERIAL USED:
 Generally, thermoset plastics (such as epoxy,
polyester, phenol-formaldehyde, vinyl ester,
silicone) are processed by transfer molding
process, but certain thermoplastic materials
can also be processed.
APPLICATIONS
 This process is widely used to encapsulate
items such as integrated circuits, plugs,
connectors,pins, coils, and studs.
 It is suitable for molding with ceramic or
metallic inserts which are placed in the mold
cavity. When the heated polymer fills the
mold it forms bonding with the insert
surface.
 Transfer molding is also used for
manufacturing radio and television cabinets
and car body shells.
RUBBER TRANSFER MOLDING
 Processes involved are:transfer molding unlike
compression molding uses a closed mold system.The
process begins with the piece of uncured rubber that
has been performed to a controlled weight and shape.
 The perform is placed into the portion of the mold
called a “pot” located between the top plate of the
mold and the ram (image right).
the ram is closed which is closed (transfers)the uncured
rubber into the cavity(s) through a runner and gate
system.
 The material is held under high pressure and
temperature to activate the cure system in the rubber
compounds (rubber is vulcanized ).The cycle time is
established to reach an optimal level of cure .
 At the end of the cycle ,the parts are
removed or ejected from the cavities and the
next cycle begins .
RUBBER TRANSFER MOLDING
ADVANTAGES
 Shorter production cycle times compared to
traditional compression molding supports
high precision molding applications. Closed
mold transfer supports molding of complex
geometries and over-molding.
DISADVANTAGES OF TRANSFER MOLDING
VS. OTHER RUBBER MOLDING METHODS
 Pot system can increase gross material
weights when cold pot or other low waste
options are not utilised.
 Higher tooling cost compared to traditional
compression tools.
ADVANTAGES OF TRANSFER
MOLDING

 Fast setup time and lower setup costs

 Low maintenance cost
 Plastic parts with metal inserts can be made
 Design flexibility
 Dimensionally stable
 Uniform thickness of parts
 Large production rate
DISADVANTAGES OF TRANSFER
MOLDING
 Wastage of material
 Production rate lower than injection
molding
 Air can be trapped in the mold
ADVANTAGES OF COMPRESSION
MOLDING
 Low initial setup costs and fast setup time
 Heavy plastic parts can be molded
 Wastes relatively little material as compared
with other methods
 The molding process is cheaper as compared
to injection molding
DISADVANTAGES OF
COMPRESSION MOLDING

 Low production rate

 Limited largely to flat or moderately
curved parts with no undercuts
COMPRESSION VS TRANSFER
MOLDING
 In both processes, scrap is produced each
cycle as left over materials,called the cull.
 The TS scrap cannot be recovered.
 Transfer molding is capable of molding more
intricate shapes.
 Transfer molding lends itself to molding with
inserts ,in which a metal or ceramic insert is
placed into cavity prior to injection and the
plastics bonds to insert during molding.
 Very intricate parts can be formed in
transfer molding whereas in compression
molding bulky parts can be produced
THANK YOU