COMPRESSION

MOLDING

PRODUCT REALISATION TECHNOLOGY PRACTICUM (IC-141P)

CENTRAL WORKSHOP
INDIAN INSTIUTE OF TECHNOLOGY MANDI
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COMPRESSION MOLDING 2
1. Introduction 3

Compression molding process is one of the low cost molding methods as compared to injection molding
and transfer molding. It is a high pressure forming process in which the molten plastic material is
squeezed directly into a mould cavity by the application of heat and pressure to conform to the shape of
the mold. The schematic of compression molding process is shown in figure 1.
Due to excellent properties and relatively low material and manufacturing costs, the use of fibre
reinforced polymer composites have increased during the last decades. One method that is suitable for
large scale productions of e.g. lightweight vehicle components is compression moulding of sheet
moulding compound (SMC). Although the technique has been considerably improved since it first was
introduced, some further improvements need to be done. The main reason why it has not come in wider
use in the vehicle industry is unsatisfactory conditions of the surface finish of parts manufactured due
to voids.

2. Working Principle

In this process, the predetermined amount of charge of plastic material is placed in the lower half of a
heated mold cavity. The plastic material is preheated before inserting into the mold cavity to reduce the
temperature difference between the material and the mold cavity. The mold cavity is closed with upper
movable half mold and pressure is applied to compress the material in to the mold cavity. This causes
the raw material to be squeezed out to take the shape of the mold cavity. The application of the heat and
pressure increases the polymerization process. Hence, plastic material is cured. The temperature of the
mold cavity is usually in the range of 130-200°C. Generally, the hydraulic pressure is required in the
range of 7-25 MPa to squeeze the plastic material. The mold cavity is then cooled for sometimes so that
molded plastic part gets solidified. The mould cavity is then opened and the final product is taken out
with the help of ejector pin. The molded part may require the finishing operation.
In compression molding, the charge of plastic material may be inserted into the mold cavity either as a
powder, granules or as a preformed. The manufacturing cycle time (heating, cooling, and part ejection)
may be long (about 1-6 minutes). For high production rate, it is desirable to have multi cavity molds.
Compression mold cavity can also be available in a wide variety of shapes and sizes; therefore plastic
products can be manufactured into different shapes and sizes. There are four important factors to be
considered before compression molding process:
Amount of plastic material (charge)
Heating time and melting temperature of plastic material
Pressure required to squeeze the material in to the mold cavity
Cooling time
Two different types of molding compounds i.e. bulk molding compound (BMC) and sheet molding
compound (SMC) are commonly used in compression molding process. In bulk molding compound,

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the plastic materials are blended with fillers and short fibers and placed into the mold cavity. In SMC,
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the long fiber sheet is usually cut according to the mold cavity and placed into the mold surface. The
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resin is placed on the fiber sheet. It is a layer by layer making process. The process is completed until
desired thickness is obtained. The long fiber sheet results in better mechanical properties as compared
with the bulk molding compound products. In both the molding compounds (BMC and SMC), the
plastic materials are conformed to the mold cavity, with the application of heat and pressure.

Figure 1 Compression Molding Setup

There are several types of compression molding machines, each designed to cater to specific
requirements and applications. The choice of machine depends on factors such as the type of material
being molded, production volume, part complexity, and precision. Here are some common types of
compression molding machines:
1. Hydraulic Compression Molding Machine:
Hydraulic machines use hydraulic systems to generate the pressure required for compression molding.
They provide high force capabilities, making them suitable for molding large and complex parts.
Hydraulic machines offer precise control over pressure and speed during the molding process.

2. Mechanical Compression Molding Machine:

Mechanical machines use mechanical mechanisms, such as toggle or crank presses, to generate the
required pressure.
They are known for their energy efficiency and are suitable for moderate-precision molding
applications.
Mechanical machines are often used for molding thermosetting materials.

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3. Vacuum Compression Molding Machine:
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Vacuum compression molding machines incorporate a vacuum system to remove air and gas from the
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mold cavity during the molding process.
Vacuum assistance helps eliminate voids and trapped air in the molded parts, resulting in higher
quality components.
This type of machine is commonly used for molding parts with complex geometries or parts that
require minimal porosity.

3. Advantages and Disadvantages:

Advantages: High precision, reduced material waste, good surface finish, suitable for large-scale
production.
Disadvantages: Longer cycle times, limited complexity compared to injection molding.

4. Applications:

Compression molding is used in industries such as automotive, aerospace, electronics, and consumer
goods. It's ideal for producing components with specific mechanical properties, electrical insulation,
and heat resistance.

5. Preparation and Setup

Material Preparation: Pre-process raw materials to the required form (granules, pellets, sheets). Measure
materials accurately for consistent results.
Mold Preparation: Clean and apply mold release agents to prevent sticking. Assemble molds and install
any inserts, if necessary.
Temperature and Pressure Settings: Set appropriate temperature and pressure parameters based on
material specifications.

6. Compression Molding Process

Loading the Mold: Place pre-measured material into the mold cavity. Close the mold and ensure proper
alignment.
Closing the Press: Position the mold in the press, ensuring proper alignment and clamping. Activate the
press's safety features and initiate the closing sequence.
Application of Temperature and Pressure: Apply pressure gradually to prevent flash and maintain
uniform material distribution. Raise the temperature to initiate curing.
Curing Time: Monitor the curing time based on material specifications. Avoid over-curing, which may
lead to brittleness.
Cooling and Demolding: After curing, allow the part to cool within the mold. Open the press carefully
and remove the part. Clean the mold if necessary.

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Experiment Compression Molding
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Aim Making of ASTM D3039 standard specimen for tensile test using thermoplastic 3
polymer and synthetic fibers.
Drawing

Material required Thermoplastic polymer

pellets (PLA, HDPE)
Equipment and Mold
tools required Vernier Caliper
(Please illustrate Silicon Spray
equipment and tools Nylon hammer.
using appropriate Sand paper
drawings) File

Procedure Clean the mold using sand paper.

Measure the weight of thermoplastic pellets and fibers.
Carefully put the pellets and fibers inside the mold cavity.
Provide the required time, temperature and pressure in the compression
molding machine according to material used.
Use the gloves to remove the samples.
Carefully remove the prepared samples using nylon hammer.
Finishing of the sample using grinding machine.
Precautions Ensure that all the switches are closed of compression molding machine
before putting the sample inside the machine.
Don’t directly put the hands in machine, always use the gloves.
Properly shut down the compression molding press after the use,
following manufacturer guidelines.

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