INJECTION MOLDING OF

THERMOSET PLASTICS

BY PRADEEP SHETTY
THERMOSET INJECTION
MOLDING MACHINE
PHOTO OF PLASTICIZING
THE RESIN
PHOTO OF INJECTION
OFTHE RESIN
PHOTO OF CROSSLINKING
PHOTO OF EJECTION
How injection molding works?
Difference between injection molding
of thermoset and thermoplastics

 Barrel
 Screw
 Mold temperature
BARREL
Process characteristics

Production Rate - high

Can produce intricate parts
Can produce a wide range of part
sizes with different press sizes.
Tooling cost - high
What is thermoset material?

A material, such as an epoxy or polyester

resin, which has the property of
undergoing a chemical reaction by the
action of heat, catalyst, ultraviolet light,
etc., to become a relatively insoluble and
infusible substance. They develop a well-
bonded three-dimensional structure upon
curing. Once hardened or cross-linked,
they will decompose rather than melt.
Some of the thermoset materials

Phenolics
Urea
Melamine
Unsaturated polyester
Specialty of the thermoset polymers for
injection molding

Delayed curing even at higher temperature

Good flow properties

Fast reaction at tool temperature

Improved wear characteristics

 TEMPERATURE IN degree C
MATERIAL NOZZLE CYLINDER MOLD MATERIAL

PHENOLIC 80-100 55-75 170-190 110-130

UREA 85-115 65-80 130-150 120-140

MELAMINE 90-110 65-80 160-170 115-135

UN-SATURATED POLYESTERS 70-100 50-70 170-200 70-100

THERMAL PROFILE OF IM
Rheology

 HEAT EXPOSURE TIME

 TEMPERATURE
 SHEARING
Rheology of Thermoplastics and
Thermosets
Advantages of Injection
Molding

Material handling is reduced

Advantages of Injection
Molding

Longer and smaller diameter core

pins may be used
Advantages of Injection
Molding

Parting line flash can be held to

minimal thickness if the mold is
designed properly and well
maintained
Advantages of Injection
Molding

Injection molding of thermoset

materials lends itself to
automating the process which can
result in lower piece costs.
Disadvantages of Injection
Molding

The total amount of scrap

produced during injection molding
will usually be higher than that for
compression molding
Disadvantages of Injection
Molding

Warpage can be a problem in

injection
Disadvantages of Injection
Molding

The filling of the parts through

one or two gates produces parts
that have knit lines.
Applications

Phenolics:
Electrical plug and sockets
circuit board
cutlery handles
Applications

Melamine-formaldehyde:
Dinnerware
Kitchen utensils
Bathroom accessories
THANK YOU