Polymers and

Polymer Processing
Lecturer: Dr. Ebenezer Annan

Extrusion
Injection Molding
Blow Molding
Thermoforming
Rotomolding
Learning Objectives:
Please read on properties for the ff.
thermoplastics: Polyesters, polyimides, Silicones
Polymer materials & Bonds
• Primary Bond -
Covalent Bonding
• Secondary Bonds
–
• van der Waals
• Dipole Bonds
• Hydrogen Bonds
• Tg
• Glass Transition
Temperature
• MW
• Molecular Weight
• The combination of
these two properties will
be a great starting point
for identifying any
polymer material
Polymer Processing
Learning Objectives:
 P olym er Fam ily Tree

T herm oplastics T herm osets/E lastom ers

W ill reform w hen m elted W ill not reform

Not Cross-Linked Cross-linked

90% of m arket 10% of m arket

Polyethylene E poxy
33% M elam ine Form alde hyde
V inyls Phenolic
16% Polyester (unsaturated)
Polypropylene Polyim ide
15% Polyurethane
PM M A S om e are therm oplastic as w ell.
ABS S ilicone
Nylon Urea Form aldehyde
Polycarbonate
S aturated Polyester
PE E K
Polyurethane
S om e are therm osets as w ell.
PV C
 Major Processes

• Extrusion
• Injection
Molding
• Blow Molding
• Thermoforming
• Rotomolding
Polymer Processes
Extrusion Product Examples
Extrusion
 Extrusion
• Basically involves melting
polymer pellets and
extruding them out through
a two dimensional die.
• Produces long, thin products
• Coating for electrical wire
• Fishing Line
• Tubes, etc.
Injection Molding Product Examples

Nylon
sheaves
Injection Molding
Injection Molding Machine Basics
Injection Molding Machine Operating Sequence

 Mold closes and screw

begins moving forward for
injection

The cavity fills as the screw

moves forward as a plunger

 The cavity is packed as

the screw continues to
move forward as part
solidifies
 Injection Molding Machine Operating Sequence,
ctd
• The cavity cools as the gate freezes
off and the screw begins to retract to
plasticize material for the next shot

• The mold opens for part ejection

• The mold closes and the next cycle

begins
 Co-injection Molding

1. Inject Skin 2.a. Inject Core

3. Inject Skin again

2.b. Continue
to purge sprue.
injecting core until
cavity is filled
Injecting hollow parts with complex interior Geometry
Gas Assist Injection Molding – Hollow parts
without interior control
Injection – Compression Molding

 Very similar to squeeze casting

Injection Molding of Thermosets

• Thermoplastics “set” when they cool

• Mold temperature will be set to allow full cavity fill,
while increasing production rate
• Thermosets undergo a chemical crosslinking that
produces the solid structure
• Mold temperature will be hotter usually – set to allow
full cavity fill, while accelerating the chemical reaction to
cure.
• Often called “Reaction Injection Molding” (RIM)
Blow Molding- Examples of products
Blow Molding

Extrusion Blow Molding Injection Blow Molding

Stretch (Parasin) Blow Molding

Thermoforming Products
Thermoforming
Thermoforming
Rotomolding
Rotomolding
• Used for relatively
dimensionally inaccurate
items, usually with a hollow
interior
• Can be very large
• Garbage Cans
• Kayaks
• Interior dimensions can not
be critical
• Relatively primitive and
therefore inexpensive
process