Plastic Processing Methods

Polymers
Poly = many
Mer = unit
Polymer = many units.
A polymer has a repeating structure, usually based on a
carbon backbone. The repeating structure results in large
chainlike molecules. In each polymer molecule, the atoms
are bound together by covalent bonds.
Polymer Chains
 POLYMERS
PLASTICS ELASTOMERS

THERMOPLASTICS

THERMOSETS
 Plastics

 Plastics are polymers

 Essentially they posses a chain like structure composed
of repetitive hydrocarbon units.
 Carbon makes up the backbone of the molecule and
hydrogen atoms are bonded along the backbone, for
example polyethylene, the simplest polymer structure.
 Plastics
 There are polymers that contain only carbon and hydrogen, for
example Polypropylene, polybutylene, polystyrene, and
polymethylpentene are examples of these.

 Other elements can include oxygen, chorine, fluorine, nitrogen,

silicon, phosphorous, and sulfur
 Polyvinyl chloride (PVC) contains chlorine

 Nylon contains nitrogen.

 Teflon contains fluorine.

 Polyester and polycarbonates contain oxygen.

 General Characteristics of Polymers
 Polymers can be very resistant to chemicals, for
example, consider all the cleaning fluids in your home
that are packaged in plastic.
 Polymers can be both thermal and electrical
insulators, for example
 Consider all the appliances, cords, electrical

outlets and wiring that are made or covered with

polymeric materials
 Thermal resistance is evident in the kitchen with

pots, pans, coffee pot handles, etc.

 Fiberfill in winter jackets is acrylic.
 Polymers are very light in weight with varying degrees of
strength.
 Polymers can be processed numerous ways to produce
thin fibers or very intricate parts.
 Molded into bottles or the bodies of a cars

 Mixed with solvents to become an adhesive or a

paint.
 Shaping Processes for Plastics
 Several Processes exist:
 Injection molding

 Extrusion

 Compression molding

 Blow molding

 Rotational molding

 Thermoforming
 Injection Molding
Mold

 Polymer heated to plastic state and forced to flow into mold

(Compare to casting?)
 Typical cycle times are 10 to 30 secs.
Injection Molding
Extruder Schematic
Plastic Extrusion
 Plastic Extrusion Machines
Hopper
Controls

Heater and
Pump Mold

Examples of Different Types of Screws

Rotational Molding
 Blow Molding
 Air used to inflate softened plastic into hollow geometry inside
a mold cavity
 Typically thin-walled vessels, e.g., bottles, containers, etc.

 Consists of two primary steps:

 Fabrication of the Parison (starting plastic tube)

 Blowing the tube to final desired shape

Blow Molding
1. Parison is extruded
2. Parison cut to appropriate length and sealed around a blow pin
3. Tube inflated to take size and shape of mold cavity
4. Part ejected from mold
Shaping Processes for Plastics -
Blow Molding

Injection Blow Molding

 Lower production cycles as compared to extrusion blow molding

 Less widely used

1. Parison is injection molded

2. Tube inflated to take size and shape of mold cavity
3. Part ejected from mold
Thermoforming
Compression Molding