ME2033:Manufacturing Processes
POLYMER
PROCESSING METHODS
Fabrication Techniques for Plastics, Composites & Elastomers
Eng.(Mr.) Ruwan Udayanandana
Based on DeGarmo's Materials and Processes in Manufacturing, Chapter 14
Senior Lecturer
Department of Mechanical Engineering
Email: ruwanu@[Link]
OVERVIEW
01 Introduction to Polymer 02
Casting & Blow Molding
Fabrication
03 Compression, Transfer & Cold 04 Injection Molding & Reaction
Molding Injection Molding
05 06
Extrusion & Thermoforming Rotational & Foam Molding
07 Elastomers, Composites & Process
Selection
INTRODUCTION TO POLYMER FABRICATION
Thermoplastics Thermosets Elastomers
Can be heated
Polymerisation occurs Unique rubber-like
repeatedly to
during shaping. Cannot behavior. Processed via
soft/liquid state.
be remelted. Used in calendering, extrusion,
Suitable for casting,
compression, transfer and vulcanization.
injection, extrusion &
& reaction injection
blow molding.
moulding.
Key Advantage: Fabrication processes can often convert raw material into a
finished product in a single operation, enabling complex shapes without multipart
assembly.
Source: DeGarmo's Materials and Processes in Manufacturing, Ch. 14
CASTING
CASTING
• Simplest shape-forming process
• No fillers or pressure required
• Materials: acrylics, nylons, PVC
plastisols, urethanes
• Thermoplastics melted & poured
into shaped containers
• Thermosets cured at 65–95°C in-
mold
• Products: sheets, films, rods, lenses,
gears
• Lustrous appearance, wide range of
colors
BLOW MOLDING
BLOW MOLDING
• Converts thermoplastic PE, PVC, PP, PEEK into
seamless hollow containers
• Parison (hollow tube preform) made by
extrusion or injection
• Expanded against mould by air/gas at 2–4 MPa
• Mold cooled → halves separated → product
ejected
• Multilayer blow molding achieves enhanced
strength
• Mould materials: Be–Cu alloys, aluminum, tool
steel
• Applications: bottles, fuel tanks, bumpers,
ductwork
COMPRESSION · TRANSFER · COLD MOLDING
Compression Molding Transfer Molding
• Widely used for thermosetting
polymers
• Premeasured granules/preforms
placed in open heated cavity
• Heated plunger applies 10–150 MPa
• Material flows & fills cavity; heat sets
polymer
• Products: electrical switchgear,
appliance housings
COMPRESSION · TRANSFER · COLD MOLDING
Cold Molding
• Uncured thermosetting material pressed cold
• Cured separately in the oven after ejection
• Faster & more economical than compression
• Drawback: poor surface finish & lower precision
• Used for low-cost industrial components
COMPRESSION · TRANSFER · COLD MOLDING
Compression
Transfer Molding
Molding Cold Molding
• Thermoset resin loaded into
separate 'pot'
• Material forced into closed mold by
plunger
• Combines benefits of compression +
injection
• Excellent for inserts & intricate
shapes
• Limitation: material waste in pot,
sprue & runners
INJECTION MOLDING
Most widely used high-volume process — the polymer equivalent of metal die casting
1 2 3 4 5
Feed Melt Inject Pack Eject
Plastic granules fed Plunger forces Superheated melt
Pressure maintained Mold opens; ejector
from hopper by material through driven through nozzle
during solidification pins release part
gravity heated torpedo at 35–140 MPa
• RIM (Reaction Injection Molding) uses
• Thermoplastics & some thermosets
reactive liquid streams for large parts
compatible
• Excellent detail, tolerances & surface
• Pressures: 35–140 MPa (5–20 ksi)
finish
• Clamping designs: toggle, hydraulic,
• High tooling cost — economical for large
hydro-mechanical
volumes
INJECTION MOLDING
EXTRUSION
• Continuous process for constant cross-
section profiles
• Rotating screw feeds & melts pellets in
heated barrel
• Melt forced through a shaped die at a
controlled rate
• Cooled by water bath or air; cut to length
or coiled
• Co-extrusion bonds two or more
materials into one profile
• Products: pipes, rods, wire insulation,
films, sheets, profiles
• High output rates; low operating cost
THERMOFORMING
• Thermoplastic sheet heated to working temperature
• Formed over male or female mold by vacuum/pressure or
mechanical force
• Cooling hardens part; excess strip recycled
• Infrared radiant heaters common for continuous rolls
• Short cycle time (few minutes)
• Limitation: non-uniform wall thickness due to stretching
• Products: luggage, trays, fridge panels, shower enclosures
THERMOFORMING
ROTATIONAL & FOAM MOLDING
ROTATIONAL MOLDING FOAM MOLDING
• Blowing agent introduced into polymer
• Powdered/liquid resin loaded into closed melt or mix
mold • Gas expands to create cellular / foam
• Mold rotated biaxially in oven — structure
material coats interior • Structural foam: solid skin + foamed core
• No pressure required — low tooling cost (high stiffness-to-weight)
• Uniform wall thickness & stress-free • Flexible foams (PU): cushions, padding,
parts insulation
• Materials: PE, PVC, nylon, polycarbonate • Rigid foams (PS, PU): packaging, thermal
• Best for large hollow shapes: tanks, insulation boards
kayaks, playground equipment • Density reductions of 10–95% achievable
• Longer cycle times vs. injection molding • Applications: automotive interiors,
packaging, construction
ELASTOMERS & COMPOSITE FABRICATION
Processing of Rubber & Elastomers Composite Fabrication Categories
• Calendering: sheets / coated fabrics between rollers
• Particulate: filler in matrix (e.g., carbon black in rubber)
• Extrusion: hoses, seals, gaskets
• Laminar: bonded layers/sandwiches (e.g., fiberglass panels)
• Vulcanization: cross-linking with sulfur/peroxides for
• Fiber-reinforced: continuous or chopped fibers (CFRP, GFRP)
strength
Fiber-Reinforced Composite Processing Methods
Hand Layup Filament Winding Pultrusion RTM Autoclave Cure
Manual fiber placement; low Continuous fiber wound on Continuous fiber pulled through Resin injected into closed fiber High pressure + heat for
cost, low volume rotating mandrel; pipes & tanks resin & die; rods, beams preform mold aerospace-grade laminates
PROCESS SELECTION GUIDE
Process Material Volume Tooling Cost Key Advantage
Casting TP / TS Low Low Complex shapes, integral color
Blow Molding TP High Medium Hollow seamless containers
Compression TS Medium Medium Simple to moderate shapes
Transfer Molding TS Medium Medium Complex shapes + inserts
Injection Molding TP / TS High High Complex, precise, high-volume
RIM TS (liquid) Medium Low Large structural parts
Extrusion TP High Low Continuous profiles, films
Thermoforming TP Medium Low Large thin-walled sheets
Rotational Molding TP Low Low Large hollow shapes
Foam Molding TP / TS Medium Medium Lightweight, insulation
TP = Thermoplastic | TS = Thermoset | Source: DeGarmo's Materials and Processes in Manufacturing, Ch. 14
SECONDARY OPERATIONS & DESIGN FOR FABRICATION
Machining of Plastics Finishing & Joining Design Considerations
• Use polymer properties as
• Integral color reduces need design advantages: light
• Conventional cutting tools
for painting weight, corrosion
usable; sharp tools
• Finishing: printing, hot resistance, electrical
essential
stamping, vacuum insulation
• Straight-flute drills or
metallizing, electroplating • Account for lower
'dubbed' twist drills
• Joining: hot-gas welding, strength/stiffness vs metals
preferred
ultrasonic vibration, • Avoid thermal cycling —
• Carbide tools for high-
soldering-iron technique creep at elevated
speed cutting
• Adhesive bonding common temperatures
• Laser machining eliminates
for dissimilar materials • Minimize wall thickness
fine dust health hazard
• Snap-fits exploit low variation to reduce sink
• Water / soluble oil coolants marks
modulus; self-tapping
prevent discoloration
screws also used • Draft angles critical for
mold release
KEY TAKEAWAYS
Process selection depends on material type (TP/TS/elastomer), part geometry, production
→
volume, and cost targets
→ Thermoplastics offer versatility — injection, blow, extrusion, thermoforming all applicable
Thermosets excel in heat resistance and stiffness; compression & transfer molding are
→
primary routes
Composites enable exceptional strength-to-weight — fiber-reinforced plastics dominate
→
aerospace & automotive
Single-step fabrication from raw polymer to finished part is a major economic advantage
→
over metals
Secondary operations (machining, joining, finishing) extend design freedom and product
→
quality
DeGarmo's Materials and Processes in Manufacturing, Chapter 14 | Polymer Processing Methods