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Introduction
This article will take an in-depth look at plastic trim.
The article will bring more detail on topics such as:
Principle of Plastic Trim
Types of Plastic in Plastic Trim
Types of Plastic Extrusion Methods
Types of Plastic Trim
Applications and Benefits of Plastic Trim
And Much More...
Chapter 1: Principle of Plastic Trim
This chapter will discuss what plastic trim are, including how they are manufactured.
What is a Plastic Trim?
Plastic trim products are extruded linear profiles that can be made to any length. Because of its ability to attach, hold, and seal, plastic trim has many applications. Plastic, HDPE, LDPE, butyrate, PVC, acrylic, and vinyl extrusions and trim are made across several industries. PVC is the most commonly used material for making plastic trim.
The construction industry uses plastic trim extensively for window insulation and trim, outdoor/indoor siding and trim, door frame insulation and trim, and bumpers and guards on sharp edges and corners. Appliance manufacturers make use of flexible vinyl and PVC trim for doors of microwave ovens and stove sealants, while vehicle industries use trim for exterior and interior fenders. Furniture, recreational and marine industries also utilize plastic trim for multiple applications. Well-known types of plastic trim are edge trim, in-house decorative trim, fender flare trim, U trim, drip rail trim, lip trim, and J trim.
Manufacture of Plastic Trim
Unlike injection molding, which produces three-dimensional products, plastic profile molding produces two-dimensional objects. The plastic profile molding process is straightforward and intuitive. Plastic extrusion is a high-volume manufacturing process in which a polymer material is melted and formed continuously while being enriched with the desired additives.
First, raw thermoplastic material is put into an extrusion barrel using a top-mounted hopper. The raw material (polymer), in the form of granules, is gravity fed into the hopper and falls on a rotating screw in the feed throat driven by an electric motor. The screw design varies according to the material and the finished product design.
Next, the screw's rotation propels the plastic into a heated barrel. As the plastic moves through the barrel, the screw's channel or thread narrows, compressing the plastic. The barrel is heated by three or more individual Proportional Integral Derivative (PID) controllers that create zones of steadily increasing temperature.
Depending on the intended use, the process may call for additives to change the attributes of the plastic trim. Projects may need colorants, UV inhibitors, or other options.
After heating, the molten plastic is fed continuously through a two-dimensional die opening and then delivered in the form of several blocks. The plastic’s melting temperature is usually higher than the set temperature for the controllers. This extra heat is produced by combining shear friction (shear heat) and compressive force. When the molten plastic reaches the screw’s end, the molten plastic is then mixed well and pushed via a screen pack, which is held by a breaker plate, sieving impurities and eliminating the material’s rotational memory. Finally, the filtered molten plastic is pushed through the die. The die gives the finished plastic trim the required profile and shape. After leaving the extruder, the plastic trim is pulled and cooled. The cooling method depends on the shape and profile of the plastic trim.
In summary, extrusion is a process in which a substance is pushed with a tool with a particular shape called a die to produce a continuous and permanent cross-sectional profile. Extrusion molding works by feeding the plastic through a die. The shape of the die is a cross-section of the required part – the trim.
Manufacturing Steps
The manufacturing steps can be summarized as follows:
Plastic extrusion – The plastic is heated and pushed via a heated chamber using a screw.
Molding – Plastic is forced through a die, producing the part's final shape.
Cooling – The extruded plastic trim is cooled.
Spool or cut – The continuous plastic trim is cut or spooled into lengths.
Extrusion machines are relatively cheap compared to other industrial machines, such as CNC or injection molding, since they are less intricate and do not need very high levels of accuracy. Due to the simple shapes, the dies are also less costly, with tooling costs that are a fraction of the cost of molds for injection molding. Just like injection molding, extrusion molding is a continuous procedure, making the cost of extruded plastic trim very low.
Shapes and forms produced with plastic extrusion are limited to objects with continuous shapes, such as I-sections, T-sections, U-sections, L-sections, and circular or square sections.
Some factors to consider for extrusion are lead time (weeks), cycle time (seconds or continuous), setup cost, cost per part, and medium volume to high volume applications (<1000 parts).
Chapter 2: Leading Plastic Trim Producing Machines
There are various machines available to produce plastic trim in the United States and Canada. These machines are important in today's society because they enable the efficient and cost-effective production of plastic trim components used in various industries, contributing to the manufacturing of essential products, reducing waste, and supporting the economy. Below, we discuss a few of these leading machines.
Model: Arburg Allrounder
Manufacturer: Arburg
The Arburg Allrounder series is known for its versatility and precision. These injection molding machines come in various sizes, allowing for flexibility in molding different types and sizes of plastic trim components and are equipped with advanced control systems that enable high repeatability and accuracy in production. The Allrounder series is popular due to its reliability, speed, and energy efficiency, making it a preferred choice in the industry.
Model: KraussMaffei GX Series
Manufacturer: KraussMaffei
The KraussMaffei GX series of injection molding machines are well-regarded for their high performance and advanced technology. They are designed for precision molding with excellent control over the molding process. The GX series incorporates features such as efficient drive systems, user-friendly controls, and a robust build. This series is a popular choice for producing plastic trim due to its ability to handle complex molds and high production volumes.
Model: Sumitomo (SHI) Demag IntElect Series
Manufacturer: Sumitomo (SHI) Demag
The Sumitomo (SHI) Demag IntElect series is known for its energy efficiency and precise molding capabilities. These machines use advanced servo technology, providing significant energy savings compared to traditional hydraulic machines. The IntElect series also offers high-speed and high-precision molding, making it suitable for producing intricate plastic trim components with tight tolerances.
Model: Husky HyPET Series
Manufacturer: Husky Injection Molding Systems
The Husky HyPET series is a popular choice for producing plastic bottles and containers, including various types of plastic trim. This series is designed for high-speed production and offers excellent productivity with rapid cycle times. Furthermore, the HyPET series includes features like quick mold change systems, advanced controls, and precise shot-to-shot consistency, making these machines suitable for demanding production requirements.
Model: Milacron Maxima Series
Manufacturer: Milacron
The Milacron Maxima series is a line of large-tonnage injection molding machines that can be used for producing various plastic trim components. These machines are known for their robust construction, reliability, and high-performance hydraulics. The Maxima series offers excellent shot-to-shot repeatability, which is essential for consistent quality in plastic trim production.
Remember that the popularity and suitability of a specific machine can vary depending on the requirements of the plastic trim production process. Before choosing a machine, it's essential to assess your specific production needs, the size and complexity of the components, and other factors to ensure the machine aligns with your business objectives.
Chapter 3: Types of Plastic and Plastic Extrusion Methods
This chapter will discuss the types of plastics used in plastic trim and the types of plastic extrusion methods.
Types of Plastic in Plastic Trim
Plastics are available with thousands of base derivatives, chemistries, and additions that cover a huge range of aesthetic and functional properties. Plastic is split into two main types, thermosets and thermoplastics, to simplify the procedure of finding the best material for a given component.
Thermoplastics
Thermoplastics are the most common type of plastic, and they are what is used in plastic trim. The main feature that differentiates them from thermosets is their ability to go through many solidifying and melting cycles without substantial degradation.
Thermoplastics are commonly supplied as small bits or sheets heated and shaped into the desired form using different manufacturing processes. The process is totally reversible because no chemical bonding happens, making melting or recycling and reusing thermoplastic feasible.
Common types of thermoplastics include:
Polyvinyl Chloride (PVC)
PVC is a popular, adaptable synthetic plastic polymer. It is a commonly used plastic type that comes in different forms for added flexibility. In its most stiff form, PVC is a good material for trim.
Polypropylene (PP)
This flexible polymer is used to make plastic films for labeling and packaging. Its tough resistance to chemicals, acids, and solvents, along with its low friction surface and sanitary finish, aid in protecting delicate content inside. It is also used for everyday household products such as decorative trim.
Polyethylene Terephthalate (PET)
PET is one of the more generally utilized injection molded plastics. PET has an aesthetically appealing finish and works well for branded products. PET is also commonly utilized in textiles, where it is commonly known as polyester and is valued for its strength and damage resistance. In addition, PET can be recycled easily, adding to its sustainability properties.
Low Density Polyethylene (LDPE)
LDPE is another well-known thermoplastic produced from petroleum. It is malleable with low tensile strength and high ductility. LDPE is applied in making trim, food trays, bin liners, plastic bags, computer parts, and floor tiles. Its smooth surface finish is lightweight and simple to keep clean.
Acrylonitrile Butadiene Styrene (ABS)
ABS is a common type of transparent plastic. It is durable and used as a glass substitute for aesthetic or safety reasons. It can be produced clear or in a color that matches a company’s branding. This product is good for fender flares, trim, pots, and containers for creams, waxes, lotions, serums, and children’s toys like plastic building blocks. ABS also functions very well with 3D printing methods.
Styrene Acrylonitrile (SAN)
SAN is an old plastic used in the injection molding process. It has been vastly exceeded by Acrylonitrile Butadiene Styrene, but it may still be present in industrial applications. SAN is transparent, rigid, and durable, providing excellent hygienic and protective properties. The polymer chains take color and print easily, so they can be used for branded packaging, advertising, and warning signage. It also insulates well, so it is applied in thermally insulated products such as trim seals.
Polystyrene
Polystyrene is naturally transparent, soft, and resilient to damage from sudden impacts, so it is a valued protective packaging material. Like other polymers, polystyrene can be formed in any size, shape, and color.
Plastic Extrusion Methods
Depending on the die’s shape, different plastic trim can be produced using many available extrusion processes stated below:
Tubing Extrusion
This type of extrusion is used for the extrusion of pipes and tubes. Air with positive internal pressure can also be applied in this procedure. After leaving the die, the pipe or tube is pulled into a cooling chamber, where it is usually water cooled.
Medical tubing and drinking straws are made using extrusion, often known as the extruded tubing technique. This method is similar to conventional extrusion until the die step when a pin or mandrel is put into the die to extrude the hollow parts. In some instances, the pin exerts positive pressure on the internal cavities.
For some purposes, it is necessary to create tubings with several lumens or holes. To produce the appropriate number of lumens, tooling is designed with many pins placed in the die's core. The pins are frequently accessible with air pressure from a variety of sources. By adjusting the pressure applied to each pin, it is simple to alter the size of the individual lumens.
Blown Film Extrusion
Blown film extrusion is for manufacturing plastic film tubes via continuous sheeting. In this procedure, the molten film tube is cooled. Then, it leaves the die to create a partially solid tube, blown to enlarge to the required size and film thickness.
Blown film extrusion is the most popular method for creating continuous films, typically used for packaging. The procedure begins with melting the plastic in the extruder, after which the molten polymer enters an annular die head and is shaped into a plastic tube. One extruder per material is needed to create multilayer films. Their melt strands are joined inside the die head to create a plastic tube with concentric layers.
Nip rollers lift the film tube upward once it emerges from the die while it is still plastic. Simultaneously, the film tube is blown with compressed air to create the correct film thickness and width. The exterior of the tube is exposed to chilled air. The film bubble is gradually flattened into "lay-flat" tubing when the film approaches the nip rollers after cooling. The film is delivered via the nip rolls to roll winders and in-line slitters at the line’s end.
Sheet Film Extrusion
This type is for the extrusion of plastic films or sheets too thick for blowing. After leaving the die, the sheets are cooled and pulled through an array of cooling rolls. The die also regulates the sheet’s thickness.
Paper or film products like plastic sheets or films are produced using the extrusion technique. The necessary cooling is achieved during the extrusion of these polymeric products by drawing through a certain group of cooling rolls, often three or four in number. Calendar or "chill" rolls are other names for these cooling rollers. However, extremely rapid running creates "nerve," a problem that develops when the heat in the extruded plastic is not given enough contact time to disperse.
The rolls in the plastic sheet extrusion determine the sheet's thickness and surface texture and provide the necessary cooling. This is specifically done in the case of structured rolls (such as smooth, levant, Haircell, etc.). In addition, co-extrusion is frequently used to apply one or more layers to obtain different qualities like soft touch or "grip," Ultraviolet light, matte surface, or energy reflection.
Over Jacket Extrusion
This type of extrusion is used for coating wire. In this procedure, the wire is pulled between the center of a die. A pressure tool is used if adhesion is needed between the coating and the wire. In this type, the wire is coated in plastic melt while in the die and pressurized while exiting the die. If adhesion is not needed, a jacketing tool is used, and wire is covered by the molten plastic as it leaves the die.
Extruding a polymer jacket of different thicknesses around a core of high-performance fibers adds protection against mechanical, environmental, and chemical harm.
The fiber core may be twisted, parallel, or in the shape of a rope. Each polymer jacket material is chosen from a large selection of polymers to maximize flex, chemical, temperature, and UV resistance per the particular needs of the application.
Considerations When Choosing a Plastic Trim Material
The following factors are to be considered when choosing a manufacturing process for plastic trim products:
Form
Do the parts have complicated internal structures or strict tolerance requirements? Depending on the design geometry, manufacturing choices can be few or require substantial design for manufacturing optimization (DFM) to make them inexpensive to produce.
Cost/Volume
What’s the overall or the yearly volume of trim planned to be manufactured? Some manufacturing procedures have high front expenses for setup and tooling but produce components that are low cost on a per-part basis. In comparison, low-volume manufacturing procedures have low start-up expenses. Due to slow cycle durations, less automation, and physical labor, cost per component remains constant or marginally reduces only when volume increases.
Lead Time
How fast do the parts or finished plastic trim need to be produced? Some procedures make the first components in 24 hours, while setup and tooling for particular high-volume production procedures take months.
Material
What strains and stresses will the plastic trim products have to endure? The best material for a specified application is determined using several factors. For example, the cost should be balanced against aesthetic and functional requirements. The ideal characteristics for a specific application must be compared with the available options in a given manufacturing procedure.
Leading Manufacturers and Suppliers
Chapter 4: Types of Plastic Trim
Many types of plastic trim with equally close tolerances may be fabricated using plastic extrusion just by changing the die in which the plastic melt is pushed. The construction industry uses plastic trim fairly extensively, and appliance manufacturers utilize vinyl and flexible PVC trim for stove and refrigerator door sealants. Automotive industries utilize profiled trim for exterior and interior fenders and trim. As stated earlier, plastic trim types include edge trim, J trim, decorative trim, brush guard trim, fender flare trim, drip trim, and lip rail trim.
J Trim
Plastic J trim, also called siding channels, are uneven molded extrusions that leave one end of the trim marginally shorter than the other. This gives it a “J” form from the trim's side profile. These J trim can come in numerous abrasion-resistant materials such as PVC, metal, vinyl, and more.
Plastic J trim products are perfect for cable and wire management systems since they are utilized to “trim” and offer a “finished” edge. Like U trim, this design also gives itself to decorative frames, and they may work better as cap molding fixed with clear tape or white foam adhesive. Plastic J trim are frequently utilized for store merchandising, directories, and signage with materials such as acrylic, poster board, and more.
Edge Trim
Edge trim cover rough and sharp edges of machines and equipment to improve safety and handling. They protect the material underneath and the attached devices on its edges (like cables). They also offer extra aesthetic appeal. Edge trim are made from various flexible plastics and polymeric materials. A metal core is commonly present in edge trim to improve its capability to clamp onto edges.
Edge trim cover edges like metal sheets, wood, and ceramics. They are used in vehicle seats, tables, windows, ceilings, PC cabinets, shelving, machine guards, and other furniture.
Decorative Trim
Decorative trim is molding that acts as the "crowning" architectural appeal of a room since it decorates the change between the ceiling and walls. Crown molds, also called cornice molding, typically boast complicated silhouettes, although various types of crown molding are available. Other types of decorative trim are chair rail, casing, picture frame molding, dentil, and egg and dart.
Trim Seal
Trim seal covers the space between two coupling surfaces to offer insulation and impermeable sealing for freezers, refrigerator doors, vehicle tailgates and compartments, passenger doors, big and insulated vessels, and other appliances. Hence, a trim seal works as a gasket.
A trim seal might consist of co-extruded layers of polymer coated with vinyl and rubber to protect them from noise, rattling, and corrosion. They are also reinforced by a metal core to improve their grip on the edges. Service temperatures, environment (for instance, exposure to moisture and vibration), grip strength, and size are significant criteria in choosing trim seals.
Fender Flare Trim
A fender flare trim is an extension to a fender that provides extra coverage for heavily oversized or offset wheels and tires. Fender flares will keep an SUV or truck in acquiescence with Vehicle Equipment Regulations, which reduces the chances of police fines.
Co-Extruded Plastic Edge Trim
In many cases, a single thermoplastic will not offer the performance level an application requires. Co-extruded plastic edge trim joins the properties of two different thermoplastics in one piece, providing the beneficial characteristics of each.
Co-extrusions can combine flexible and rigid materials, different colored materials, thin cap stocks over thick substrates, and various other options.
Lip Rail Trim
Lip trim is often used as a decorative trim in cupboard construction but is useful enough to meet multiple needs.
Chapter 5: Applications and Benefits of Plastic Trim
This chapter will discuss the applications and benefits of plastic trim.
Applications of Plastic Trim
Plastic trim have numerous possible applications since they can be tailored to meet various needs. Any product that calls for a clean, safe, and refined finish stands to profit from applying plastic trim.
Plastic trim is advantageous to any effort to reduce damage and distortion. In addition, plastic molding has a degree of flexibility, making it perfect for usage in architectural applications as wall and ceiling trim. It can also be used for baseboard molding and doorway edging.
Trim also improves durability. It can protect industrial machines from damage, provide protection from sharp objects and edges, and make flexible bumpers. This feature of plastic trim makes it a prominent option for automotive applications. It protects both vehicles and their drivers from harm.
More applications of plastic trim are listed below:
Windows
Plastic rain gutter
Truck bed cover
Running boards
Car and other automotive door edges
Truck, van, or car edge trim
Fender flares
Other sharp, risky edges
Plastic trim products are an efficient and economical method to finish a product.
Benefits of Plastic Trim
Plastic trim products provide an economical, efficient way for manufacturers to finish the edges of many components. They see the most use in the automotive and transportation industries, but they prove valuable in several more applications.
Plastic trim molding can also help the overall visual appearance of a piece or component of machinery. When properly taken care of, molding and trim can be the difference between a component looking like a work in progress and a finished product. Plastic is also cost-efficient, so it’s a great choice for fabricators looking to enhance the aesthetics of their designs on a strict budget.
Plastic trim profiles are made from strong material to ensure dependability. They are also very safe and simple to install, needing no skills or fancy tools for installation. Plastic trim are designed with quick installation and safe holding in mind. Plastic trim molding is extruded in a variety of materials, profiles, colors, foamed profiles, finishes, and geometries.
Advantages of Plastic Trim Extrusion
There are various reasons why plastic extrusion is an economical, efficient, and practical way to produce plastic trim products.
The extrusion process makes continuous forms in varying lengths quickly and efficiently.
Products may be made in high volumes with low wastage.
Complicated shapes can be made with varying textures, thicknesses, colors, etc.
An extensive scope of sizes and shapes is possible with the complex machinery.
Various extras enhance the products’ attributes, fire resistance, durability, and lower friction or static.
Plastic extrusion tools are normally significantly cheaper than tools for other plastic manufacturing methods.
Co-extrusion is beneficial when two or more pieces of machinery are utilized to feed one die head and where many layers of materials are needed for the product.
Co-extrusion may also be used to add a top layer to enhance the plastic products’ appearance while keeping costs low with a cheaper plastic material at the trim's center.
Drawbacks of Plastic Trim Extrusion
The properties and microstructure of the plastic trim products manufactured by the extrusion molding process are uneven. The flow during extrusion is uneven, which results in uneven tissue attributes between the top layer and the center, tail, and head of the extruded product.
The operating circumstances of extrusion die are harsh, which greatly affects the durability and service life of a die.
There is low production efficiency. Save for continuous plastic extrusion, most extrusion methods can’t achieve uninterrupted production. Usually, the plastic extrusion speed is very low compared to the rolling speed. The geometric wastage loss of plastic trim extrusion production is big, and the yield is small.
Only simple forms of trim products can be produced.
The plastic trim produced using plastic extrusion are only extruded to a total thickness of 0.60 inches (15.2 mm).
Plastic extrusion produces a wide range of trim products, but it is still limited. For instance, this method cannot be used to make highly sophisticated trim parts. Additionally, only one kind of cross-section is possible at a time.
High initial costs are incurred in setting up extrusion machines. Therefore, this investment might weigh on a budget right at the beginning.
Plastic Trim vs. Wood Trim
For many years, fabricators used wood and its respective products to create trim. The terms casings and trim referred to the linear lumber parts that covered most homes' border edges and corners. However, wood trim struggled in wet locations since it is organic and rots. Therefore, the construction industry needed a material that was completely resistant to rotting and water penetration. This led to the invention of cellular PVC.
It is well known that plastic trim molding is beneficial for PVC pipes. They were once utilized only for plumbing drains. Nowadays, PVC has become popular.
The most significant differences between PVC and wood manufacturers utilize for trim molding are chemical in nature. Wood swells up when exposed to moisture, while PVC expands because of heat.
Temperatures cause PVC to shrink in winter and expand in summer. However, unlike wood trim, PVC trim will not warp from environmental reasons, making them the best choice.
Conclusion
Edge trim, internal ornamental trim, fender flare trim, U trim, drip rail trim, J trim, and lip trim are popular varieties of plastic trim available on the market. Plastic trim is widely used in the construction industry for various purposes, including bumpers and guards for sharp edges and corners, interior and outdoor siding, door frame insulation, and window insulation and trim. While the automotive industry uses custom trim for the outside and interior fenders, appliance makers employ elastic vinyl and PVC trim for microwave oven doors and refrigerator sealants. Additionally, plastic trim is used in the maritime, recreational, and furniture industries for many purposes.
For manufacturers, plastic edge trim solutions offer an affordable, effective alternative to finish the edges of many components. Although they are used most frequently in the industrial automotive and transportation sectors, they are useful in a variety of other applications as well. Plastic trim profiles are created from sturdy materials to ensure dependability. Additionally, they are highly safe and easy to install; in most cases, they don't require special knowledge or equipment. Fast installation and secure holding are priorities in the design of plastic trimmings.
Regarding various manufacturing methods utilizing plastics, extrusion is among the highest in demand. To start the plastic extrusion procedure, thermoplastic flakes or pellets are put into a hopper placed on top of a closed extruding channel. Gravity puts the raw plastic material into the extruding channel. Running down the channel length is a screw conveyor that moves the raw plastic straight towards the other end, heating and shearing the plastic using friction. Electric heaters inside the extruding channel frequently aid the screw conveyor in plasticizing, or melting, the plastic flakes so that the plastic melts before it comes out of the end of the channel. Manufacturers from several industries rely on advanced extrusion machines. With the proper plastic extrusion machinery, there is no better way to manufacture superior quality plastic trim products. As with all machines, an extrusion machine has benefits and drawbacks, but plastic extrusion is a versatile production process.
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