TOPIC 9 - METHODS, PROCESSES, AND EQUIPMENT FOR PLASTIC & RUBBER MANUFACTURING

METHODS, PROCESSES, AND EQUIPMENT FOR as thermosets) remain in a permanent solid state
PLASTIC & RUBBER MANUFACTURING after curing. Polymers in thermosetting materials
crosslink during a curing process that is induced by
PLASTIC heat, light, or suitable radiation. This curing process
 are the most common materials for producing forms an irreversible chemical bond. Thermosetting
end-use parts and products, for everything from plastics decompose when heated rather than melting,
consumer products to medical devices. Plastics and will not reform upon cooling. Recycling thermosets
are a versatile category of materials, with or returning the material back into its base ingredients
thousands of polymer options, each with their own is not possible.
specific mechanical properties.
 A variety of plastic manufacturing processes have THERMOPLASTICS COMMON TYPES
been developed to cover a wide range of 1. Acrylic/PMMA – Poly(methyl methacrylate) - is a
applications, part geometries, and types of plastics. transparent thermoplastic often used in sheet form as
For any designer and engineer working in product a lightweight or shatter-
development, it is critical to be familiar with the resistant alternative to
manufacturing options available today and the new glass. Although not a type
developments that signal how parts will be made of familiar silicabased
tomorrow. glass, the substance, like
many thermoplastics, is
HOW TO CHOOSE THE RIGHT PLASTIC often technically classified
MANUFACTURING PROCESS: as a type of glass (in that it
1. FORM - Depending on the geometry of a design, is a noncrystalline vitreous
manufacturing options may be limited, or they may substance.
require significant design for manufacturing (DFM) 2. Acrylonitrile butadiene styrene (ABS) - is a
optimization to make them economical to produce. terpolymer made by polymerizing
styrene and acrylonitrile in the
2. VOLUME/COST - Some manufacturing processes presence of polybutadiene. The
have high front costs for tooling and setup, but proportions can vary from 15% to
produce parts that are inexpensive on a per-part basis. 35% acrylonitrile, 5% to 30%
In contrast, low volume manufacturing processes have butadiene and 40% to 60%
low startup costs, but due to slower cycle times, less styrene.
automation, and manual labor, cost per part remains
constant or decreases only marginally when volume
increases. 3. POLYAMIDE – is a
polymer with repeating
3. LEAD TIME - Some processes create first parts units linked by amide
within 24 hours, while tooling and setup for certain bonds. Polyamides occur
high volume production processes takes months. both naturally and
artificially. Examples of
4. MATERIAL - The optimal material for a given naturally occurring
application is determined by a number of factors. polyamides are proteins,
Cost must be balanced against functional and such as wool and silk.
aesthetic requirements. Consider the ideal Artificially made
characteristics for your specific application and contrast polyamides can be made through step-growth
them with the available choices in a given polymerization or solid-phase synthesis yielding
manufacturing processes. materials such as nylons, aramids, and sodium
poly(aspartate). Synthetic polyamides are commonly
TYPES OF PLASTICS used in textiles, automotive industry, carpets,
Plastics come in thousands of varieties with different kitchen utensils and sportswear due to their high
base chemistries, derivatives, and additives that are durability and strength.
formulated to cover a wide range of functional and
aesthetic properties. To simplify the process of finding 4. Polylactic acid (PLA) - is a thermoplastic polyester
the material best suited for a given part or product, let’s formally obtained by
look first at the two main types of plastic: condensation of lactic
thermoplastics and thermosets. acid with loss of water
(hence its name). It can
THERMOPLASTICS - are the commonly used also be prepared by ring-
plastics. The main feature that sets them apart from opening polymerization of
thermosets is their ability to go through numerous lactide, the cyclic dimer of
melt and solidification cycles without significant the basic repeating unit.
degradation. Thermoplastics are usually supplied in the
form of small pellets or sheets that are heated and 5. Polycarbonate (PC) – are a group of thermoplastic
formed into the desired shape using various polymers containing carbonate groups in their
manufacturing processes. The process is completely chemical structures.
reversible, as no chemical bonding takes place, which Polycarbonates used in
makes recycling or melting and reusing thermoplastics engineering are strong, tough
feasible. materials, and some grades
are optically transparent.
Thermosetting Plastics - In contrast with They are easily worked,
thermoplastics, thermosetting plastics (also referred to molded, and thermoformed.
TOPIC 9 - METHODS, PROCESSES, AND EQUIPMENT FOR PLASTIC & RUBBER MANUFACTURING
6. Polyether ether ketone (PEEK) - is a colorless
organic thermoplastic polymer in the 12. Polyoxymethylene (POM) - is
an engineering thermoplastic
used in precision parts requiring high stiffness, low
friction, and excellent dimensional stability. Typical
applications for injection-molded POM include high-
performance engineering components such as small
gear wheels, eyeglass frames, ball bearings, ski
polyaryletherketone(PAEK)family, used in engineering
bindings, fasteners, guns, knife handles, and lock
applications. PEEK is a semicrystalline thermoplastic
systems. The material is widely used in the automotive
with excellent mechanical and chemical resistance
and consumer electronics industry.
properties that are retained to high temperatures.
THERMOSETTING COMMON TYPES
7. Polyethylene (PE) – is the most
common plastic in use today. It is
1. CYANATE ESTER - are chemical substances in
a polymer, primarily used for
which the hydrogen atom of the phenolic OH group
packaging (plastic bags, plastic
is substituted by a
films, geomembranes, containers
cyanide group. Cyanate
including bottles, etc.).
esters based on a
bisphenol or novolac
derivative are used in the
8. Polypropylene (PP) - it is
production of resins.
belongs to the group of
Cyanate esters can be
polyolefins and is partially
cured and post cured by
crystalline and non-polar.
heating, either alone at
Its properties are similar to
elevated temperatures or at
polyethylene, but it is
lower temperatures in
slightly harder and more
presence of a suitable catalyst.
heat resistant. It is a white,
mechanically rugged
2. EPOXY - refers to any of the basic components or
material and has a high
cured end products of epoxy resins, as well as a
chemical resistance.
colloquial name for the
epoxide functional
9. Polyvinyl chloride (PVC) - is the world's third-most
group. Epoxy resins,
widely produced synthetic plastic polymer
also known as
(afterpolyethylene and polypropylene. PVC comes in
polyepoxides, are a
two basic forms: rigid (sometimes abbreviated as
class of reactive
RPVC) and flexible. The rigid form of PVC is used in
prepolymers and
construction for pipe and in profile applications such as
polymers which contain
doors and windows. It
epoxide groups.
can be made softer and
more flexible by the
3. POLYURETHANE - is a polymer composed of
addition of plasticizers,
organic units joined by carbamate (urethane) links.
the most widely used
While most polyurethanes are thermosetting polymers
being phthalates.
that do not melt when
heated.Polyurethanes are
10. Polycarbonate (PC)- are a group of thermoplastic
used in the manufacture of
polymers containing carbonate groups in their
high-resilience foam
chemical structures. Polycarbonates used in
seating, rigid foam
engineering are strong, tough materials, and some
insulation panels,
grades are optically transparent. Polycarbonate is a
microcellular foam seals
durable material. Although it has high impact
and gaskets, spray foam,
resistance, it has low
durable elastomeric wheels and tires.
scratch resistance.
Therefore, a hard
4. SILICONE - is a polymer made up of siloxane. They
coating is applied to
are typically colorless, oils
polycarbonate eyewear
or rubber-like substances.
lenses and
Silicones are used in
polycarbonate exterior
sealants, adhesives,
automotive
lubricants, medicine,
components.
cooking utensils, and
thermal and electrical
11. Polystyrene (PS) - is a synthetic aromatic
insulation.
hydrocarbon polymer made from the monomer known
as styrene. Polystyrene
5. VULCANIZED RUBBER -
can be solid or foamed.
is an example of type of
It is a rather poor barrier
rubber polymer. A
to oxygen and water
substance which has a
vapor and has a
molecular structure built
relatively low melting
completely from a large
point
TOPIC 9 - METHODS, PROCESSES, AND EQUIPMENT FOR PLASTIC & RUBBER MANUFACTURING
number of similar units bonded together known as 3. CURE: The casting cures in the mold until it solidifies
polymers. Polymers has high molecular mass. They are (subjecting the mold to heat can accelerate the cure
also called macromolecules. time for certain polymers).
4. DE-MOLD: The mold is opened and the cured part is
TYPES OF MANUFACTURING PROCESSES removed.
 3D PRINTING - create threedimensional parts 5.TRIMMING: Casting artifacts like flash, sprues, and
directly from CAD models by building material layer seams are cut or sanded away.
by layer until a complete physical part is formed.
As 3D printers require no tooling and minimal  ROTATIONAL MOLDING - also called
setup time for a new design, the cost of producing rotomolding is a process that involves heating a
a custom part is negligible in comparison with hollow mold filled with powdered thermoplastic and
traditional manufacturing processes. rotated around two axes to produce mainly large
hollow objects. Processes for
MANUFACTURING PROCESS rotomoldingthermoset plastics are available as
1. PRINT SETUP: Print preparation software is used for well, however less common.
orienting and laying out models within a printer’s build MANUFACTURING PROCESS
volume, adding support structures (if needed), and 1. CHARGING: Plastic powder is loaded into the mold
slicing the supported model into layers. cavity, and then the remaining parts of the mold are
2. PRINTING: The printing process depends on the installed, closing the cavity for heating.
type of 3D printing technology: fused deposition 2. HEATING: The mold is heated until the plastic
modeling (FDM) melts a plastic filament, powder melts and adheres to the mold’s walls, while
stereolithography (SLA) cures liquid resin, and selective the mold is rotated along two perpendicular axes to
laser sintering (SLS) fuses powdered plastic. ensure a uniform plastic coating.
3. POST-PROCESSING: When printing is complete, 3. COOLING: The mold is slowly cooled while the mold
parts are removed from the printer, cleaned or washed, remains in motion to ensure that the skin of the part
post-cured (depending on the technology), and the does not sag or collapse before fully solidifying.
support structures removed (if applicable). 4. PART REMOVAL: The part is separated from the
mold, any flashing is trimmed away.
 CNC Machining - includes mills, lathes, and
other computercontrolled subtractive  VACUUM FORMING - is a manufacturing
processes. These processes start with solid method where a plastic is heated and formed,
blocks, bars, or rods of metal, or plastic that are typically using a mold. Vacuum forming machines
shaped by removing material through cutting, vary in size and complexity from low-cost desktop
boring, drilling, and grinding.Unlike most other devices to automated industrial machinery.
plastic manufacturing processes, CNC machining Commonly vacuum formed parts include product
is a subtractive process where material is packaging, shower trays, car door liners, boat
removed by either a spinning tool and fixed part hulls, and custom products like dental aligners.
(milling) or a spinning part with a fixed tool (lathe).
MANUFACTURING PROCESS
MANUFACTURING PROCESS 1. CLAMPING: A plastic sheet is clamped in a frame.
1. JOB SETUP: CNC machines require an intermediary 2. HEATING: The sheet and the frame are moved close
step of generating and validating toolpaths (CAD to to heating elements, which makes the plastic soft and
CAM). Toolpaths control where the cutting tools move, pliable.
at what speeds, and any tool changeovers. 3. VACUUM: The frame is lowered, and the plastic is
2. MACHINING: The toolpaths are sent to the machine stretched over the mold, while vacuum is activated to
where the given subtractive process begins. Depending suck all the air out from between the plastic and the
on the desired shape of the final product, the workpiece mold, thus forming the part.
may need to be set in a new position so that the tool 4. COOLING AND RELEASE: Once the part has been
head can reach new areas. formed over the mold, it must be given time to cool
3. POST-PROCESSING: After manufacture, the part before removal. Cooling system like fans and sprayed
is cleaned and deburred, trimmed. mist are sometimes used to reduce cycle times.
5. TRIMMING: Once the part is released, excess
 POLYMER CASTING - a reactive liquid resin or material is cut off either by hand or with a CNC
rubber fills a mold which reacts chemically and machine.
solidifies. Typical polymers for casting include
polyurethane, epoxy, silicone, and acrylic.  INJECTION MOLDING - Injection molding (IM)
Polymer casting is relatively inexpensive, with works by injecting molten thermoplastic into a
little initial investment, but thermoset polymers for mold. It is the most widely used process for
casting are usually more expensive than their mass manufacturing of plastic parts. Despite the
thermoplastic counterparts and molding cast parts high initial costs and slow ramp up, injection
is laborintensive molding has no match for high volume
MANUFACTURING PROCESS applications. Once the tooling is up and running,
1. MOLD PREPARATION: The mold is coated with a cycle times only take a few seconds, and millions
release agent to facilitate demolding, and often of high-quality parts can be produced at a fraction
preheated to a material specific temperature. of the cost of all other manufacturing processes.
2. CASTING: The synthetic resin is mixed with a curing
agent and poured or injected into the mold, where it fills MANUFACTURING PROCESS
the mold cavity. 1. MOLD SETUP: If the part has inserts, these are
added either by hand or robotically. The mold is closed
by a hydraulic press.
TOPIC 9 - METHODS, PROCESSES, AND EQUIPMENT FOR PLASTIC & RUBBER MANUFACTURING
2. PLASTIC EXTRUSION: Small plastic pellets are
melted and extruded through a heated chamber by a
screw.
3. MOLDING: The molten plastic is injected into the
mold.
4. COOLING AND RELEASE: The part cools in the
mold until it is solid enough to be ejected, either
mechanically or by compressed air.
5. POST-PROCESSING: Sprues, runners and any
flash (if applicable) is removed from the part, often
automatically as part of the mold opening.

 EXTRUSION MOLDING - are works by pushing

plastic through a die. The shape of the die is a
crosssection of the final part. Extrusion machinery
is relatively cheap compared to other industrial
machines like CNC or injection molding as it is less
complex and does not require such high levels of
machine accuracy. Due to the simple shapes, dies
are also less expensive, with tooling costs that are
a fraction of molds for injection molding.

MANUFACTURING PROCESS
1. PLASTIC EXTRUSION: Plastic is heated and
pushed through a heated chamber by a screw.
2. MOLDING: Plastic is forced through a die that
creates the final shape of the part.
3. COOLING: The extruded plastic is cooled.
4. CUT OR SPOOL: The continuous shape is spooled
or cut into lengths.

 BLOW MOLDING - is a manufacturing

technique used to create hollow plastic parts by
inflating a heated plastic tube inside a mold until
it forms into the desired shape. Blow molding is the
most common process for creating hollow plastic
products at scale. Typical applications include as
bottles, toys, automotive components, industrial
parts, and packaging.

MANUFACTURING PROCESS
1. MOLD SETUP: Small plastic pellets are melted and
formed into a hollow tube, called the parison or preform
(depending on the blow molding subtype).
2. MOLDING: The parison is clamped into a mold and
gets inflated by pressurized air until it takes the shape
of the inside of the mold.
3. COOLING AND RELEASE: The part cools in the
mold until it is solid enough to be ejected.