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Introduction
This article will take an in-depth look at thermoplastic molding.
The article will bring more detail on topics such as:
Principle of Thermoplastic Molding
Thermoplastic Molding Process and Machinery
Thermoplastic Injection Mold Types and Materials
Applications and Benefits of Thermoplastic Molding
And Much More...
Chapter 1: Principle of Thermoplastic Molding
This chapter will discuss the definition and process of thermoplastic molding.
What is Thermoplastic Molding?
Thermoplastic molding is a manufacturing process that works to create fully functional parts by injecting plastic resin into a pre-made mold. Thermoplastic polymers are more widely used than thermosetting polymers in injection molding. The main reason for this is that thermoplastics are plastics that can be repeatedly softened by heating and solidified by cooling, making them highly recyclable materials.
Materials left over from a previous molding process cycle are re-grinded and added back to an injection chamber along with virgin pellets. This addition is limited to 30% of the bulk material, as it can degrade the plastic's original physical properties.
Thermoplastic molding has several sub-categories, such as rapid injection molding, which is best utilized in fine-tuning prototypes before a product is given the go-ahead for production. Another sub-category of thermoplastic injection molding is production injection molding; this is best utilized for full product runs. Developers get to use the thermoplastic injection molding process for many applications, as it can produce anything from cell phone cases to car door panels with good accuracy and surface finish.
This process is the industry standard for producing plastic parts. This reason allows developers to be certain that they are putting out a quality product if they go this route in the development process. The thermoplastic injection molding industry has changed over the years: initially, it aimed mostly at producing combs and buttons. Now it has transformed into the production of a wide range of products for many industries, including automotive, medical, aerospace, consumer products, toys, plumbing, packaging, and construction. Thermoplastic injection molding, or injection molding, uses certain materials' thermoplastic properties to inject a softened plastic into a mold to create an impression. This thermoplastic molding technique provides the best quality for large and very large series productions.
The principle of plastic injection is based primarily on the use of heat to soften a thermoplastic (TP) material in the form of pellets. The softened material is kneaded and injected into an endless screw. The rotation of this screw and the pressure added after that can insert the material into a mold. This inserted material takes on the impression of the mold and is then cooled; after it cools, the object takes on solid form and can be removed from the mold. The removed mold can then be reused for another process of injection. This method is ideal because it allows the duplication of many identical objects of high quality. This fact is made possible due to the ability of the mold to be reused with the right material. This process is why thermoplastic injection is particularly suited to large or very large series production.
Another advantage is that designed parts require little or no subsequent machining. However, this method has a cost because it requires the design of a steel mold, which caters to the duplication of many series parts. This disadvantage is why it is not recommended for designs of small series. An example of a preferred solution is silicone molding.
Thermoplastic Injection Molding vs. Thermoset Molding
The way thermosets are made differs from thermoplastics in several aspects, and both the categories require varied treatment during the injection molding process. Included below are a few differences when molding thermosets and thermoplastics.
Thermosets
Thermoplastics
When producing parts, the cold material is injected into a hot mold
When producing parts, the plastic material is melted and injected into a mold
Can’t be remolded or reshaped
Can be remolded and recycled
Forms a permanent chemical bond
100% reversible, as no chemical bonding takes place during the process
Comparatively difficult to surface finish
Thermoplastics result in accurate, flexible, and pleasing surface finishes
Does not require high heat and high pressure compared to thermoplastics molding
Requires high heat and high pressure
Thermosets are made by condensation polymerization
Thermoplastics are made by additional polymerization
The production process includes compression, transfer, and casting
The production process includes injection molding, extrusion, and blow molding
Some of the end products that come from thermosetting injection molding include: Handles of tools, billiard balls, insulation, computers parts, television parts, any electronic equipment, gardening equipment, tools, sprockets, and cooking utensils
Some of the end products that come from thermoplastic injection molding include: Vacuum cleaners, toys, machine screws, gear wheels, kettles, packaging film, sacks, power tool casings, toasters, gas pipes, and fittings
Disadvantages of thermosets are: unable to be recycled, and they release emissions referred to as volatile organic compounds (VOCs)
Disadvantages of thermoplastics are: they are expensive, easily melt when heated, and are hard to prototype
Chapter 2: Thermoplastic Molding Process and Machinery
The thermoplastic injection molding process cycle takes place in an injection molding machine which mainly consists of the injection unit, clamping unit, and the mold.
Clamping Unit
In the clamping step, the halves of the mold are shut before the molten plastic is injected. They are then held after the molten material has dwelled in the cavities. This process occurs in the clamping unit, which is responsible for several functions, such as applying sufficient clamping force to resist the injection force. It does this while keeping the mold halves shut during the injection step until the dwelling step is reached.
The clamping unit is also responsible for ejecting the molded part after the dwelling step, closing and opening the mold plates between molding cycles, and holding the mold plates in a proper alignment.
The clamping unit is made of:
The platen, which holds the halves of the mold when it is attached to the injection molding equipment.
The stationary platen works to hold half of the front mold and houses the nozzle of the injection unit. This nozzle of the injection unit is directly aligned with the front mold half. The movable platen is also contained. This movable platen acts in moving half of the rear mold by sliding on the tie bar during the opening and closing of the mold.
The tie bar functions in supporting the movable platen during translation. The tie bar can align the mold plates together. The contained size of the tie bar can limit the size of the mold.
The clamping system in the clamping unit is responsible for translating the movable platen toward the stationary platen. An injection molding machine contains three clamping systems: toggle clamps, hydraulic clamps, and hydro-mechanical clamps.
Toggle clamps in the clamping unit are ideal for injection molding machines with low tonnage requirements. The toggle clamps are equipped with an actuator that functions by moving the crosshead forward. This function is able to extend the crosshead links that have the movable platen attached to its end.
Hydraulic clamps can be easily regulated and positioned at a wide tonnage ranging from 150 to 1,100 tons. The hydraulic pressure attained is used to translate the movable platen and develop the force required to secure the mold halves during the injection step.
Hydro-mechanical clamps can result in a larger clamping tonnage of above 1,000 tons. The function of hydro-mechanical clamps includes a combination of the toggle and hydraulic clamping systems. A hydraulic cylinder is used in the translation of the movable platen. The hydraulic cylinder is then fixed mechanically in its position. Once the halves of the mold are closed, a high-pressure hydraulic cylinder is used to build the required tonnage.
Injection Unit
In the injection step, the raw plastic pellets are melted and then transported to the mold. This takes place in the injection unit. The injection unit is responsible for several things, including supplying molten plastic to fill the mold cavities. The volume of plastic injected into the mold is referred to as a shot. The volume of the shot depends on the part's volume.
The injection unit supplies heat which melts and homogenizes the plastic pellets before injecting them into the mold. In addition, it supplies enough injection speed and pressure to push the molten plastic and fill the cavities of the mold.
The injection unit comprises:
The hopper, which is a large container in which the raw plastic pellets are fed.
The hopper contains an opening at the bottom where the pellets are introduced to the threads of the reciprocating screw inside the barrel.
The barrel contains the reciprocating screw and heaters that are jacketed on its periphery.
The heaters jacketed on the periphery provide thermal energy to melt the plastic pellets to their molten and viscous state.
The reciprocating screw is able to push the plastic through the length of the barrel. It does so by rotating and sliding axially. A hydraulic cylinder supplies the injection pressure. As the plastic travels along the length of the barrel, it gains fluid properties due to the combination of pressure, heat, and friction. The molten plastic is assembled in front of the screw, and a non-return valve hinders its backflow. The most common injection system in modern injection molding machines is the reciprocating screw.
The use of a screw pre-plasticizer is another injection mechanism. This injection system has separate barrels for injecting the plastic into the mold and melting it. The first barrel contains a mechanism that is similar to the reciprocating screw. Once the plastic has passed through the first barrel, it then proceeds to the second barrel. This second barrel uses a plunger to transfer the molten plastic to the mold.
Older injection molding machines use a single barrel, a plunger-type injection system, to melt and inject the plastic.
The nozzle directs the molten plastic to the mold cavities. The nozzle is located in the stationary platen and is directly aligned with the front mold half.
Dwelling and Cooling
Once the molten plastic is moved into the mold, it is allowed to settle inside the cavities. The holding pressure is used to replace the injection pressure in this step to compact the molten plastic during its solidification. The cooling process proceeds once the molten plastic comes in contact with the surface of the cavities. Cooling is made possible by a coolant system inside the mold. Shrinkage of the part may occur during cooling; therefore, an additional melt is allowed to flow to compensate for shrinkage that occurs during cooling. After cooling it for a required time, the mold halves are separated, and the molded part is ejected.
Ejection Process
The cooled part is separated from the mold in the ejection process stage. The ejection system, which is found in the clamping unit, eases the removal of the molded part from the mold cavities. The ejection system is made up of an actuating ejector bar that acts to push the ejector plate with ejecting pins. The ejecting pins drive out the solidified part from the open mold plates at the end of the molding cycle. Enough ejecting force must be supplied because the part adheres to the mold during cooling. A mold release agent is used to help in removing the molded parts from the mold cavities. The agent can be reapplied before the start of the clamping step after a few molding cycles. It may also be permanently fixed on the surface of the mold cavities.
Trimming Process
Trimming is the last step in the production of injection-molded plastics. Here, excess plastics resulting from the flow of the molten plastic are cut from the molded part. Then each molded unit is separated from the rest of the molded parts. The process of trimming takes place with separate equipment. During injection of the molten plastic, the mold channels, which are the sprue, runners, and gates, are filled. The molten plastic in those channels can then solidify together with the melt inside the cavities. Flashes may also form on the edges of the part. After cooling, the surplus plastic materials adhere to the part that must be cut.
The Mold Tool
The mold mainly comprises two plates fastened to the clamping plates. The rear mold half is linked to a movable plate which allows the opening and closing of the mold. It is also adjacent to the ejection system of the clamping unit. Before the start of the molding cycle, the two plates must be free and clean from contamination. The mold cavity is the shaped section in the mold plates that provides the plastic parts their final form. When the molten plastic flows into the cavity, it fills up the shape of the hollow space and gains its volume.
The front mold half contains most of the volume. One or more cavities can be found in a mold. The parting line is a line found in the closed mold halves that reflects their separation. A parting line may be a straight line or a curve in complex tooling designs. Air can vent in the parting line more easily, so the molten plastic tends to move in this region. Some finished parts may have a visible line or curve, which reveals that the two sides of the part are formed on different plates.
Mold Channels
In the mold channels:
The locating ring functions by aligning the nozzle to the front mold plate.
The sprue is the first passageway of the melt from the front half of the mold and the nozzle of the injection unit. The sprue is the main channel that has several runners connected.
The runner supplies the molten plastic to the mold cavity.
The gate controls the flow of the molten plastic into the cavities by narrowing its flow path. The gate is positioned at the end of each runner, wherein the molten plastic is introduced. Multiple gates can be included in a cavity.
Other mold tool features include air vents that eliminate entrapped gasses inside the mold and the cooling channel, which facilitates the dissipation of heat to a coolant.
Injection Molding Parameters
The injection molding parameters include:
Clamping pressure, also referred to as tonnage, is the pressure needed to hold the mold halves during the injection step. The clamping pressure complements the applied injection pressure. The part's surface area, part depth, and size of the mold are also noted when calculating and optimizing the clamping pressure.
Insufficient clamping force can result in leakage of the molten plastic, leading to the development of flashes. Part defects, failures on the mold, and failing equipment itself result when excessive clamping force is applied. Cracked platen, fractured hydraulic cylinders, mold plates, and crushed mold vents are some of the potential damages experienced on the equipment in the long run. These damages are induced by excessive clamping force.
Injection pressure is the pressure supplied by the plunger or screw to force the molten plastic through the cavities until it is 95% filled. The flow characteristics of the molten plastic, such as viscosity and shear rate, also affect the required injection pressure. Molten plastics with a higher viscosity tend to have more resistance to the flow. This factor, therefore, creates a need for a higher injection pressure to maintain the shot's volumetric flow rate.
Injection pressure should also be monitored. Part defects and early solidification of the molten plastic in the mold channels can result due to insufficient injection pressure. Excessive injection pressure causes pressure build-up because the internal pressure inside the cavities rises when it is 95% filled, potentially leading to the premature opening of the mold.
Holding pressure is applied after the cavity is 95% filled until the solidification of the gates. This holding pressure is about half of the injection pressure. Holding pressure is essential in improving the compactness of the molded part, controlling shrinkage, and cooling the part.
Injection speed refers to the rate at which the screw or the plunger rotates to transfer the molten plastic to the mold cavities. In most functions, it is best to increase the injection speed to fill the cavities with molten plastic in the shortest possible time.
Chapter 3: Top Thermoplastic Molding Companies
There are numerous companies performing thermoplastic molding in both the United States and Canada. The thermoplastic molding industry is well-established in North America, and you can find a wide range of companies offering these services to various industries. Here are five prominent companies known for their thermoplastic molding capabilities:
Proto Labs, Inc.
Proto Labs is a Minnesota-based company that offers rapid prototyping and on-demand production services, including thermoplastic injection molding. They utilize advanced manufacturing technologies and automated systems to streamline the production process, reducing lead times and ensuring high-quality parts. The company has an online quoting system that enables customers to upload their CAD designs and receive quick quotes for their molding projects. Proto Labs' expertise, speed, and customer-focused approach have contributed to its popularity in the thermoplastic molding industry.
Nypro, a Jabil Company
Nypro, now a part of Jabil, is a global leader in contract manufacturing, including thermoplastic molding. Headquartered in Massachusetts, Nypro has extensive experience in providing design, tooling, molding, and assembly services for various industries, such as healthcare, consumer electronics, and automotive. Their state-of-the-art facilities and commitment to innovation have made them a preferred choice for complex and large-scale thermoplastic molding projects.
Berry Global, Inc.
Berry Global, headquartered in Indiana, is a leading manufacturer and supplier of plastic packaging and engineered materials, including thermoplastic molding products. The company serves a wide range of industries, including food and beverage, healthcare, personal care, and more. Berry Global's success is attributed to its diverse portfolio, extensive distribution network, and continuous investment in advanced molding technologies.
U.S. Farathane Corporation
U.S. Farathane, located in Michigan, specializes in thermoplastic injection molding and provides engineered plastic solutions for the automotive industry and beyond. They are known for their focus on innovation and customization, offering end-to-end services from product design and engineering to manufacturing and assembly. Their ability to meet stringent industry standards and supply chain demands has contributed to their prominence in the thermoplastic molding sector.
Crescent Industries, Inc:
Crescent Industries, based in Pennsylvania, is a full-service provider of custom thermoplastic molding solutions. They cater to various industries, including medical, aerospace, electronics, and consumer products. The company's reputation for precision molding, stringent quality control, and responsive customer service has earned them a strong position in the market.
It's essential to remember that the landscape of the industry may have changed since this last update. It is recommended that one conducts further research and consults recent sources to get the most up-to-date information on these, and other, companies and their thermoplastic molding capabilities.
Leading Manufacturers and Suppliers
Chapter 4: Thermoplastic Injection Mold Types and Materials
This chapter will discuss the different types of injection molds and the common types of thermoplastics used in injection molding.
Types of Plastic Injection Molds
An injection mold is selected depending on the part geometry, production volumes, budget, and tool design. The type of injection mold may affect the manufacturing cost and the quality of the components.
Low/High Cavitation
Single cavity molds are manufactured to produce one part per cycle. These molds are a cost-effective approach when part volumes are low because they are less expensive to build. They have a shorter lead time. The disadvantage of these molds is a higher piece part cost in molding production.
Multi-cavity molds produce more parts per cycle. Some of the included advantages are increased capacity, and lower piece part costs since more parts can be produced within a comparable cycle time.
Family Mold
A family mold contains a single mold base with two or more different cavities, allowing for the production of two or more different parts. All the produced parts can be formed simultaneously, or shut-offs can be used to isolate production to selected cavities. For great results in molding, the parts should be similar in shape, resin, size, and anticipated volumes.
Having similar parts is especially important if the intention is to run all parts at the same time. Automation may be needed to separate the pieces during or after production. A family mold can provide cost savings and versatility if mold cost is a driving factor and volumes are low.
Unscrewing Molds
Unscrewing molds are commonly used to create threaded holes within a plastic part. Unscrewing molds are automated with small drive systems, including rack & pinion, electric, or hydraulic motors. These drive systems are tied into the process and rotate threaded features to extract undercut features. Threads can either be internal or external, and the extraction is tied into the press cycle. Multi-shot or multi-component tooling allows a product designer to use two or more materials that are not similar on one part within the same cycle.
There are many reasons why different materials would be needed, including different physical properties or simply appearances. Unscrewing molds often use multiple manifolds within one tool. Multi-shot tooling can be an ideal solution for complicated products or color changes within a product line. This requires multiple machine nozzles, hot runner systems, and mold rotation.
Hot Runner Molds
Hot runner components utilize a temperature-controlled manifold to reduce or eliminate runner scrap from the cycle. Injection points can be outside or directly inside the part. Cycle times are increased as a sprue system, also called a runner system, is a determining factor in the cycle of the mold. Eliminating the runner saves expensive wasted material.
The controller must be sized to match the manifold in the mold. Through material and cycle time savings in the long run, they often compensate for themselves. This is particularly true in uses that need expensive engineering-grade resins or high annual volumes.
Cold Runner Molds
Cold runner molds are more traditional tools that utilize sprues and runners to gate into the part. This is the least complicated form, but it may result in larger amounts of wasted material and slower running cycles. Depending on the area of use, a percentage of wasted material may be re-grinded and re-processed for future use. However, this can affect the physical properties of the resin. Dealing with more advanced, high-cost materials such as medical and engineering-grade resins may lend to using an efficient hot runner. This also applies to the inability to re-grind components in an application.
Insulated Runner Molds
Insulated runner molds resemble more traditional cold runner molds. They use cartridge heaters or other methods of heating to form a surrounding layer of molten resin. This results in forming an insulated cull to create a similar effect to a hot runner system. This approach is less expensive than using a hot runner, which requires a temperature controller. It also allows for faster color and material changes. The disadvantage is that insulated runners are not suitable for all types of materials and therefore do not work well with more demanding engineering-grade resins.
Two/Three Plate Mold
Three plate molds are grouped as cold runner tools. By adding a third plate to the runner system, one can locate the injection point in virtually any location on the tool. The process is usually less expensive than adding a hot runner system. However, this type of mold can be more difficult to automate as it often has large and unwieldy runners.
Common Thermoplastic Injection Moldings
Some of the common thermoplastic injection moldings are:
Acrylonitrile Butadiene Styrene
Acrylonitrile Butadiene Styrene (ABS) is an opaque thermoplastic and amorphous polymer. Acrylonitrile butadiene styrene is a terpolymer, a copolymer consisting of three distinct monomers; in this case, they are acrylonitrile, butadiene, and styrene. These three combined can create a product that is flexible, lightweight, and moldable into many items we use in our everyday lives.
The advantage of ABS is that it allows various modifications to be made to improve impact resistance, toughness, and heat resistance. When molding is performed at a high temperature, the gloss and heat resistance of the product are improved.
Molding at a low temperature results in the highest impact resistance and strength. In addition to molded plastics, acrylonitrile butadiene styrene is used in drain pipe systems, golf club heads, and automotive parts.
Polyethylene
Polyethylene is a thermoplastic polymer that contains a variable crystalline structure. It is one of the most versatile and popular plastics and is used in an extremely large range of applications depending on the specific type.
Polyethylene is found in two common plastics: high-density polyethylene (HDPE) and low-density polyethylene (LDPE). It has high ductility levels, tensile strength, impact resistance, resistance to moisture absorption, and recyclability.
A polyethylene material with a higher density produces plastic that is stronger, more rigid, and more heat-resistant. The primary applications of this material are plastic bags, plastic films, containers, and geomembranes.
Polycarbonate
Polycarbonate plastics refer to a naturally transparent amorphous thermoplastic. These thermoplastics are put to use in the production of a variety of materials that require impact resistance and transparency, e.g. bulletproof glass.
Polycarbonate can experience large plastic deformations without cracking or breaking. As a result, polycarbonate is commonly used for greenhouses, eyewear lenses, medical devices, automotive components, and cellular phones.
Chapter 5: Applications and Benefits of Thermoplastic Molding
The applications and benefits of thermoplastic molding include:
Applications of Thermoplastic Molding
Thermoplastic molding is used to create various things such as bottle caps, wire spools, packaging, automotive dashboards, and pockets combs. This molding technology allows the production of small series with the proper material. The uses of thermoplastic injection are highly varied in the plastics industry, particularly in the automotive, packaging, medical and electronics fields. A thermoplastic injection can be ideal for the regulatory requirements and constraints in a field requiring many tests and certificates, such as the medical sector. The parts produced are mechanically equal to series production. In addition, the thermoplastic molding manufacturing technique is used to produce parts that are very small, such as electronic components, or very large, such as car body parts.
Benefits of Thermoplastic Molding
In providing good quality for the part, using the right material for the injection gives the parts made by thermoplastic molding the robustness and mechanical properties of series parts, making it ideal for carrying out tests and marketing a small series. Molds produce goods of excellent quality, and injection molding or thermoplastic injection can use very small or very large molds depending on needs while also maintaining high precision. This is why this method of rapid prototyping is used in the medical and automobile fields.
Conclusion
Thermoplastic molding is a manufacturing process that works to create fully functional parts by injecting plastic resin into a pre-made mold. Thermoplastic polymers are more widely used than thermosetting polymers in injection molding. The main reason is that thermoplastics can be repeatedly softened by heating and solidified by cooling, making them highly recyclable materials. Materials left over from a previous molding process cycle are re-grinded and added back to the injection chamber along with virgin pellets. An injection mold is selected depending on the part geometry, production volumes, budget, and tool design. The type of injection mold has the ability to affect the manufacturing cost and quality of the components.
Leading Manufacturers and Suppliers
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