Plastics are among the most popular materials for end-use products and parts. They are preferred as they are cost-effective, shatter-resistant, and lightweight. The different polymer options have varying mechanical properties affecting their manufacturing. Here are some manufacturing processes that plastic manufacturers use:
-Plastic Extrusion
In this process, plastic pellets or powder are fed onto the extrusion machine, which is heated at a controlled temperature. A screw is used to push molten plastic through a metal die to form. Once the plastic is pulled into shape, cooling starts and the product can be trimmed to the desired length.
Plastic extrusion is common in the manufacture of pipes, straws, window frames, and hoses. The continuous process works best for high-volume production because it can help keep the costs low.
-Injection Molding
Injection molding is one of the most used manufacturing processes for complex plastic items. This process uses molds made of steel or aluminum to withstand the pressure and high temperatures in production.
The machine injects molten plastic into the molds at high pressure to bring them to the desired shape. The mold opens up to eject the finished part then the plastic cools off.
Injection molding is ideal for manufacturing large, identical parts that need a high-quality surface finish. Using a mold for repetitive production avoids defects and reduces manufacturing costs.
-Rotational Molding
Rotational molding is often used in the manufacture of hollow plastic products. Place plastic polymer into the mold before heating. Once in place, the mold is closed, and it is placed into a furnace. The mold is then rotated, allowing the molten plastic to coat the inside evenly.
The mold is taken off the heat, and spray water is used to cool the mold while still rotating it. Constant rotation verifies that the molten plastic solidifies along the walls inside the mold, leaving the center hollow.
This production method is ideal for making large plastic items like water tanks. Rotational molding helps achieve a uniform wall thickness for a good-looking end product.
-Blow Molding
Blow molding is popular in producing smaller, hollow items like bottles and beakers. A plastic tube is heated and placed inside a mold to form an open object. Manufacturers use air pressure to inflate the plastic to match the mold walls. It is then ejected.
This process helps with the mass production of containers, making it cost-effective. The polymers used for blow molding are easily recyclable and safe for consumables.
-Vacuum Casting
This method uses highly sophisticated technology to create plastic items. A vacuum pulls the liquid plastic material into the mold to make small functional plastic parts. This process helps to manufacture high-quality prototypes as it produces accurate details. Air entrapment might affect the measurement of such parts, and using a vacuum sucks out all the air.
-Thermoforming
Thermoforming involves using a vacuum to stretch plastic over a die into the desired shape. Thick or thin gauge plastic is heated over a die until the material is pliable. The material is pulled into position by vacuum pressure to end up in its final shape.
This process is often helpful for manufacturing thin items like plastic cups, packaging material, lids, and boxes. Thicker gauge material can make auto body parts that need to match out the details perfectly.
-Compression Molding
During compression molding, plastic is pre-heated and placed inside a die. A cap is placed over the cavity of the die, then heat and pressure are applied. This forces the plastic to cure. Most items made using this process are thin-walled, including gaskets, O-rings, and keypad switches. Compression molding is inexpensive and less wasteful, making it ideal for factory use.
Work with the Best Plastic Manufacturer
Plastic parts and products can save you money because they are inexpensive to make and serve you for a long time. Different plastic items undergo unique processing steps, as covered throughout this article. Work with the best plastic manufacturer to enjoy accurate production results.