TRANSFER MOULDING

Concept

Transfer moulding is a method of moulding thermoset materials in a closed

mould. In this process the thermoset resin is placed into a transfer chamber where the
resin is heated until liquid. A plunger then forces the liquid resin through a sprue and
runner system into the mould cavities. The heated mould is closed during the transfer
process to allow the part to cure and solidify. After an appropriate time, the mould is
opened and the part is ejected. The part is connected to a runner system and the transfer
chamber that must be trimmed off and discarded. Standard practice in transfer
moulding requires that a small excess of charge be placed into the transfer chamber to
insure that the cavities are completely filled with each shot. This excess material, called
cull, also cures because the transfer chamber is heated and is discarded as part of the
runner system.
 Plunger

Transfer Chamber Mould

Mould Cavity

Mould

Ejector Pins (down)

Transfer moulding process - charge

heating
 Part

Transfer moulding process -

injection (transfer)
 Cull

Runner

Part

Ejector Pins (up)

Transfer moulding process - part

removal.
EQUIPMENT AND MOULDS

The pressure requirements for transfer

moulding are somewhat less than those for
compression moulding because the
material is liquid and therefore flows more
easily than do some types of compression
moulding charges. The injection pressures
are similar to those used in injection
moulding. Typically, however, a
compression moulding press is used for
transfer moulding with the appropriate
modifications made in the mould design to
provide a heated transfer chamber with a
plunger.
There are two methods of transfer moulding.

Pot transfer mould

The thermoset material is heated and liquefied in a pot or transfer chamber provided
in the mould. The plunger forces the liquid resin into the cavity. The plunger is a part
of the upper section of the mould. It is actuated by the platen of the compression
moulding machine. The area of the pot should exceed the area of all the cavities,
sprues and runners at least by 15%. This is required since the total force exerted by the
pot is required to keep the mould from opening and flashing when the liquid is injected
into the cavities.

Plunger transfer mould

In this design the material is injected by an auxiliary ram or plunger which is
a part of the transfer press. The press platens hold the mould halves together at the
required clamping force. The clamping force must be 20 to 25% above the total force
exerted by all the cavities sprues and runners when operating under full auxiliary ram
pressure. Otherwise the mould will open during injection.
Advantages of transfer
moulding 1. Moulding Cycle

2. Dimensional tolerances
3. Insert Moulding
4. Family Moulds
5. Encapsulation

Disadvantages of transfer moulding

1. Mould Cost
2. Material Cost
3. Mechanical Properties
Comparisons of transfer moulding with other moulding processes

The logical comparisons for transfer moulding are with compression

moulding and injection moulding. When compared to compression moulding,
transfer moulding has a slightly faster mould cycle because the material transferred in
has already been heated. (Compression moulding sometimes preheats the charge as
well, thus eliminating this advantage for transfer moulding).
Transfer moulding makes parts that are much more complicated than those
made by compression moulding. Part dimensions are more accurate with transfer
moulding than with compression moulding and the parts typically do not have flash,
although they do have runners, sprues, and culls.
Comparisons of transfer moulding with other moulding processes

Inserts, especially delicate inserts, and encapsulated parts can be moulded

with transfer moulding but are difficult to make with compression moulding. mould
costs are higher for transfer moulding than for compression moulding.
The relatively long flow path of the material in transfer moulding effectively
eliminates the use of resins containing fiber reinforcements. Resin orientation can
also be a problem with transfer moulding as it is with injection moulding.
Part complexity is about the same for transfer moulding and injection
moulding and so moulds are approximately the same cost. The moulding times for
transfer moulding are generally much longer than for injection moulding, reflecting
the natural differences in thermoset and thermoplastic moulding.
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