Vietnam National University Ho Chi Minh City

Ho Chi Minh City University of

Technology
Faculty of Materials Technology

Chapter 4. Polymer and

composite processing

Dr. Van-Tien Bui

Email: [email protected]
Phone: 84‐911552201
 Conten
5.
1
Thermoformin
g t 5.
5
Extrusion-based
processes

5. Compression & 5. Injection

2 transfer molding 6 molding

Rotational
5. 5. Fiber-forming
molding and 7
3 methods
sintering
Thermoset
5. 5. Composites
4 Extrusion 8 Manufacturing
Methods
 Selection
 There of plastics processing
are many processes for plastics.
Selection of a process depends on many
factors including:
- Quantity and production rate
- Dimensional accuracy and surface finish
- Form and detail of the product
- Nature of material
- Size of final product
 Selection
 There of plastics processing
are many processes for plastics.
Selection of a process depends on many
factors including:
- Quantity and production rate
- Dimensional accuracy and surface finish
- Form and detail of the product
- Nature of material
- Size of final product
 In general, plastics processes have three
Stages of plastics processing
phases:
1. Heating - To soften or melt the plastic
2. Shaping / Forming - Under constraint of
some kind
3. Cooling - So that it retains its shape
 Temperature of plastics
processing
Low temperature Softening temperature Molten temperature

- Solution casting
- Thermoforming - Injection molding
- Hand layup - Extrusion
- Foaming - Lamination
- Foaming
- Foaming
Raw materials
 Plastic raw materials include Thermosets &
Thermoplastics
 Most of plastics are supplied in particulate form
(pellets, beads, granulates) which is convenient for
● Transport and handle
● Blend (with additives)
● Store
● Feed and process
 m < Size < mm
 4.
1
Thermoformi
ng
Thermoforming process
Definition: Thermoforming, or sheet forming, is a very old polymer-
processing operation that involves heating a polymer sheet to its
softening temperature and then forming it to a desired shape using
vacuum, air pressure, and mechanical mean.
Pressure thermoforming
Materials Used in Thermoforming
Process
Thermoforming typically involves heating a sheet of
thermoplastic material and then forming it into a
specific shape using a mold. Some common
materials used in thermoforming include:
 Acrylic (PMMA)
 Polycarbonate (PC)
 Polyethylene (PE)
 Polypropylene (PP)
 Polystyrene (PS)
 Polyvinyl chloride (PVC)
Thermoforming products
Thermoforming
Advantages Disadvantages
Low machine cost High cost of raw materials
(sheets)
Low temperature requirement High scrap

Low mold cost Limited part shapes

Low pressure requirement Only one side defined by mold

Large parts easily formed Inherent wall thickness

variation
Fast mold cycles Internal stresses common
Thermoforming animation
Thermoforming process
 5.
2
Compression and
Transfer molding
5.2 Compression molding
Definition: Compression molding is a process of molding in which
a feeding material is placed into an open, heated mold cavity. The
mold is then closed with a top plug and compressed with large
hydraulic presses in order to have the material contact all areas of
the mold.
Compression
1. Charge Loading Molding Process
Place a pre-weighed amount
of material in a matched
metal mold and closing the
mold .

2. Compression
Heat and pressure cause the
material to liquify and flow
into the voids in the tool
where it chemically reacts
and hardens into the final
shape.
Materials Used in Compression
Molding
The material used in compression molding can vary
depending on the application, but some common
materials include:
1) Thermosetting polymers, such as phenolic, melamine,
and urea-formaldehyde resins
2) Rubber and elastomers, such as silicone and neoprene
3) Thermoplastic polymers, such as nylon, polypropylene,
and polyethylene
The choice of material depends on the desired properties
of the product, such as strength, durability, flexibility,
and heat resistance.
Compression Molding Products

 Kitchenware
 Rubber clothing
 Automotive parts
 Computer and
gaming equipment.
 Appliance housing.
 Medical
accessories.
Compression Molding
Advantages Disadvantages
Low capital and tooling costs Low productivity

Low mold maintenance Required additional finishing

step
Low residual stress product Limited mold depth

Retained mechanical and

electrical properties
Compression molding animation
5.2 Transfer molding
Transfer molding involves transferring a liquid or melted
materials into a heated mold cavity under high pressure. The
material then cures and solidifies in the mold to form a
specific shape. Some common materials used in transfer
molding include:
1.Thermosetting polymers,
such as epoxy, phenolic,
melamine, and silicone
resins
2.Composite materials, such
as carbon fiber, fiberglass,
and ceramic composites
3.Elastomer materials, such
as urethane and silicone
transfer molding process
 5.
3
Rotational
molding
5.3 Rotational molding
process
Materials used in rotational molding
Rotational molding involves rotating a hollow mold
filled with a thermoplastic material, typically in a
powdered form, around two perpendicular axes.
The material melts and fuses to the inside of the
mold to form a specific shape. Some common
materials used in rotational molding include:
 Polyethylene (PE), including linear low-density
polyethylene (LLDPE), high-density polyethylene
(HDPE)
 Polypropylene (PP)
 Polyvinyl chloride (PVC)
 Nylon (PA)
 Polycarbonate (PC)
 Rotational Molding
Products
 Tanks– up to 50,000 L
 Environmental products: litter
bins, road cones, bollards,
traffic dividers and road signs.
 Automotive products: diesel
fuel tanks, toolboxes and
tractor dashboards.
 Kayaks, canoes and boats
 Products for the outdoors:
garden planters, water butts
Rotational Molding
Advantages Disadvantages
Low capital and tooling costs Low productivity

Low scrap Required additional finishing

step
Low residual stress product Limited mold depth

Low pressure molding High cost of raw materials

(powder)
Ideal for large & hollow part Difficulty in controlling wall
thickness
Multi colors product Difficulty in molding ribs

Double wall product Need to precise setting time

Rotational molding
animation
Rotational
molding
process
 5.
2
Plastic
Extrusion
5.4 Extrusion
Definition: Plastics extrusion is a high-volume manufacturing
process in which raw plastic is melted and forced through a
shaped die by means of pressure to form a continuous profile.
Thermoplastic profile
extrusion
1. Barrel Extruder
- Barrel is a hollow chamber
that contains the screw to
melt and transport the
material
- The barrel is typically
made of metal
- The extruder barrel
typically consists of two
main parts: the barrel
body and the barrel
insert.
- Heating bands are
attached outside the
barrel. Heating bands are
2. Single Screw Extruders: are the most common continuous
extruders due to their various advantages like low cost, simple design,
toughness, reliability, and high performance/cost ratio.
Feed Compression Metering

Diameter
(D)

Depth Pitch

Length (L)
A typical screw consists of 3 zones:
1.Feed Zone: The flight depth is constant.
2.Transition Zone or Compression Zone: The flight depth starts to decrease.
In effect, the thermoplastic material is compressed and begins to plasticize.
3.Metering Zone: This zone has a smaller flight depth than in the mixing zone
but remains constant.
Twin Screw Extruders
Twin screw extruders can be divided into two and can be
further subdivided:
1. Intermeshing extruders
- Co-rotating extruders
- Counter-rotating extruders
2. Non-intermeshing extruders
- Counter-rotating extruders
- Co-rotating extruders
- Co-axial extruders
3. Extruder Die
• An extruder die is a component
of an extrusion machine that
shapes the molten polymer
into the desired cross-sectional
shape as it is forced through
the die opening.
• The die is located at the end of
the extruder barrel after the
filter.
 Plastic Extrusion Products
As one of the main methods of
creating plastic parts, the overall
applications of the extrusion
process are too widespread.
However, the following are some
of the most prominent areas where
plastic extrusion technologies play
an integral part.
• Pipes& Tubes
• Wire Insulation
• Windows
• Doors
• Blinds and Shades
• Cleaning Equipment
The common polymeric materials used are:
Polyethylene; Polyvinyl chloride; Polyamide; Polybutylene
terephthalate; Thermoplastic elastomers; Ethylene propylene
copolymers; Polypropylene; Fluoropolymers
Plastic Extrusion
Advantages Disadvantages
Low tooling and low part cost Limited shape complexity

Continuous process, high Surface finish limitations

productivity
Multiple materials are Material limitations
possible in extrusion
products
High mixing efficiency
Extrusio
n
animatio
n
Extrusion process
 0
1
Injection
molding
Injection molding
Injection moulding is a manufacturing process for producing parts by injecting molten
material into a mould. Injection moulding can be performed with a host of materials mainly
including metals (for which the process is called die-casting), glasses, elastomers,
confections, and most commonly thermoplastic and thermosetting polymers.
Process

● 1 - Filling / Melting Stage: The injection molding process begins by filling the hopper with
plastic pellets that feed into the screw barrel of the injection molding machine.
● 2 - Injecting / Packing Stage: Next, the screw pushes the molten plastic into the mold cavity
where it takes form and begins the cooling stage. .
● 3 - Cooling Stage: Coolant lines, typically filled with water, run through the mold to maintain
mold temperature, which helps to cool the part faster. This is highly important as the cooling
phase is the most time-consuming stage of the injection molding cycle due to plastics' insulating
properties.
● 4 - Ejection Stage: Once cooled, the mold then opens and the plastic part is ejected by the
Injection Molding Cycle
Injection Molding
Cycle
Injection
mold
Injection
mold

Steel mold
Aluminum mold
Injection molding animation
Injection molding process
 Advantages: Disadvantage:
• The main advantage of this process is • Initial cost/ setup cost of this process
that complex shapes components having is very high due to design, testing
small wall thickness (5-15 mm) can be and tooling of the whole equipment.
easily molded and removed from the die • Investment molding is generally
without damage. limited to some special kind of
• Parts which are made by injection materials like thermoplastic materials
molding have good dimensional or some polymers only.
tolerance. • High tooling cost i.e. the mould used
• The major advantage of this technique is is made by several processes and
that the scrap produced by this is very testing the overall cost of making a
less as compare to some other single mold is very high. For different
processes. parts different kind of molds are
• Parts made by injection molding process required.
are competing with parts made by
investment casting and complex
machining parts.
• This process is having high production
rate as compare to other techniques.
Applications

• Injection molding is used for making complex

shape parts of various sizes having less wall
thickness.
• Typical parts like cup, containers, toys, plumbing
fittings, electrical components, telephones
receivers, bottle caps, automotive parts and
components.
5.5 Extrusion
based
processes
Blown Film Extrusion
In the process of Blown Film Extrusion, the common resins that are used are
Polyethylenes (LDPE, HDPE and LLDPE).
Though, various other materials can also be used in this process, as a blend with
resins or even as single layers in the multi-layer film structure.

Schematic diagram of an apparatus that is used to form thin polymer films

Advantages Of Blown Film Extrusion
In a single operation, flat as well
as gusseted tubing are formed
• Regulation of film thickness and
width with the control of air
volume in the bubble
• Elimination of the end effects like
edge bead trim along with non-
uniform temperature which can
cause from flat die film extrusion
• Capability of biaxial orientation,
which allows uniformity in all
the mechanical properties
• Very high productivity
• Allows combination of different
materials as well as properties
 Application
Industry Packaging Shrink Film
Stretch Film
Bag Film
Container Liners
Consumer Packaging Film For Frozen Products
Packaging Shrink Film For Transport Packaging
Food Wrap Film
Packaging Bags
Form, Fill And Seal Packaging Film
Laminating Film Laminating of aluminum or paper used for
packaging milk, coffee, and similar products
Barrier Film Film Made of Raw Materials like Polyamides
and EVOH acting as an aroma or oxygen
barrier that are used to package food, e.g.
cold meats and cheese
Agricultural Film Greenhouse Film
Crop Forcing Film
Silage Film
Silage Stretch Film
Films For Packaging
Medical Products
Blown film extrusion process
Extrusion Blow Molding
 Extrusion Blow
-Molding
Plastic is melted and extruded into a
hollow tube (a parison)
- This parison is then captured by
closing it into a cooled metal mold
- Air is then blown into the parision,
inflating it into the shape of the hollow
container, or part
Extrusion blow molding
process
njection Blow Molding
Injection Blow Molding
- Parison is injection molded around a
blowing rod
- Injection mold is opened and parision is
transferred to a blow mold
- Soft polymer is inflated to conform to a
blow mold
- Blow mold is opened and blown
product is removed
Injection blow molding process
 Blow Molding Products
 Milk bottles
 Pharmaceutical bottles
 Antifreeze bottles
 Garbage cans
 Drums
 Fuel tanks
 Ice chests and coolers
Injection Blow Molding vs
Extrusion Blow Molding
 Blow Molding
Advantages Disadvantages
Well suited for low and high Process and material
production rates limitations
Mold cost is comparative low It is not possible to mold in
due to lower pressure holes, except after the
molding
Quick product revisions for
increased flexibility
Tooling is less expensive than
other moldings
Price per part is less than
that in rotational molding
 5.
5
Fiber-forming
methods
FIBER WHICH PROCESSED BY MELT SPINNING : Polyester, Nylons, Olefins, Polypropylene,
Saran, Sulfar etc.
Classification
Melt spinning
REQUIREMENTS OF MELT SPINNING
 The polymer should not be volatile.
 The polymer should not decompose in the molten state and the melting point.
 Polymer should be 30 degree centigrade less than its decomposition temperature.

ADVANTAGES OF MELT
SPINNING :
 Can be used for both staple and
continuous filament.  Direct and
simple process.
 No environment pollution.
 No solvent required.
 Non toxicity and no risk of
explosion.
 High production speed ( 2500 –
3000 ft/min ).
 Low investment cost.
DISADVANTAGES OF MELT
SPINNING :
 Required more proper
maintenance of the Moisture
Solution
spinning
Dry spinning
ADVANTAGES OF DRY SPINNING :
Wet spinning  It is suitable for heat sensitive polymer.
 The post spinning operation is simple.
 High spinning speeds can be easily
achieved.
 Moderate concentration of polymer is
required.
 It is relatively flexible process and
spinning conditions can be modified.
 Suitable for producing fine denier fibers.
 No need to wash the fiber.
DISADVANTAGES OF DRY SPINNING :
 Investment cost is high.
 Slow process
 Difficult to achieve exact cross section
of fibers.
 Additional post spinning process is
required.
 Toxic and risk of explosion.
 Solution
spinning
Dry spinning
Wet
spinning
ADVANTAGES OF WET
SPINNING :
 Large tows can be handled.
 Better than melt and dry
spinning for temperature
sensitive polymers.
DISADVANTAGES OF WET
SPINNING :
 Slow process ( 70 – 150
yd/min ).
 Washing to remove
impurities.
 Solvent and chemical
recovery is costly.
 Lower production rates than
melt or dry spinning due to
GEL SPINNING
 Gel spinning is a special process used to obtain high strength or other special fiber properties.
The polymer is not in a true liquid state during extrusion. Not completely separated, as they would
be in a true solution, the polymer chains are bound together at various points in liquid crystal
form.
ADVANTAGES OF GEL
SPINNING :
 Medium speed ( up to 1500
m/min).
 Suitable for liquid crystalline
polymers.
DISADVANTAGES OF GEL
SPINNING :
 Environmental pollution
hazards.
 Purification of the filament is
needed.
 Cumbersome technology
ELECTROSPINNING
Electrospinning is a fiber production method which uses electric force to draw charged threads of
polymer solutions or polymer melts up to fiber diameters in the order of some hundred
nanometers.
 Electrospinning shares characteristics of both electrospraying and conventional solution dry
spinning of fibers.
 The process does not require the use of coagulation chemistry or high temperatures to produce
solid threads from solution.
 This makes the process particularly suited to the production of fibers using large and complex
molecules.
 Electrospinning from molten precursors is also practiced; this method ensures that no solvent can
be carried over into the final product.
 5.
Thermoset
6
Composites
Manufacturing
Methods
Thermoset Composites Manufacturing
Methods
Composites manufacturing is a process that uses two or more materials to create a new material
with unique characteristics. While composites are most often thought of in terms of carbon fiber,
the process can be used with other materials including glass fiber, aramid fiber and natural
fibers.

4 Resin injection
1 Hand layup method

5 Pultrusion
2 Vacuum bag
method
6 Filament winding
3 Autoclave method

High and low temperature

7 compression moulding
1. Hand layup method:
The Hand Layup method is simple and suitable for simple components. A coat of resin is
applied on a tool surface and a layer of mat or fabric reinforcement is placed on the tool
surface. The process is repeated till the required thickness of the laminate is reached.
This is cured at 25 – 40 degree Celsius. No pressure is required.
2. Vacuum bag method:
Lay-up of laminates is covered by an airtight rubber membrane and the air under membrane
is evacuated, which helps compaction and removal of air bubbles. This is cured at 25 – 40
degree Celsius at a pressure of 1 bar.
 3. Autoclave method:
This method is similar to
the vacuum bag method.
The laid up assembly is
covered with an airtight
assembly and sealed
against the tool. The
assembly is then placed in
an autoclave where
vacuum, pressure and the
cure process is tightly
controlled.
 4. Resin injection:
This method requires top and bottom halves of tools whose shape corresponds to the desired
thickness and configuration of the part. The reinforcing materials, in the form of fabrics or mats,
are placed between the tool halves in dry plates. The resin is injected by means of vacuum. The
system is cured at 25 – 40 degree Celsius at a pressure of 1 bar.
 5. Pultrusion:
This is the reverse of extrusion. Material is pulled through a die. This method is used for
producing straight lengths of solid or hollow cross section.
 6. Filament winding:
Resin covered continuous rovings, bands or mats are placed on a rotating mandrel and
cured. This method is used to produce parts with elliptical or oval cross-sections and circular
cross sections