Injection Moulding Process: Definition, Parts, Working Principle, Defects,

Advantages, Disadvantages & Applications

The Injection Moulding Process is a manufacturing process used for producing parts or components by
injecting molten material into the mold cavity. Injection molding can be performed with only one of
these materials like glass, plastics, etc. and most commonly, thermoplastic polymers are used.

Parts of Injection Moulding Machine:

The parts of the Injection Moulding Machine are as follows.

1. Reciprocating Screw

2. Granules

3. hopper

4. heater

5. Nozzle

6. Fixed Pattern

7. Mould cavity

8. Moving Pattern

9. Final Product
 1. Reciprocating Screw:

The reciprocating screw rotates by means of a motor and the reciprocating motion is provided
by a hydraulic system.

2. Granules:

The thermoplastic granules are to be used in the Injection moulding Machine to create solid
components.

3. Hopper:

By the use of a hopper, the plastic granules are to be poured into the molding machine.

4. Heater:

It acts as a source of heat for heating the plastic granules to the molten state.

5. Nozzle:

A nozzle of the required size is to be placed at the end of the heating zone so that, molten
material enters from it and acquires the required shape.

6 and 8. Fixed Pattern and Moving Pattern:

These are the two patterns that are placed side by side so as to form a mold. Among the two
patterns, one is the fixed pattern and the other is the movable pattern.

During Solidification, the molten metal present in between these patterns can stay for some
time and after that, the moving pattern moves aside, and thereby final product is obtained.

7. Mould Cavity:

It is the place where solidification takes place between the fixed pattern and moving pattern
and the formation of the component takes place.

9. Final Product:

Thus the final product will be obtained after cooling.

Working Principle of Injection Moulding Machine:

 The reciprocating screw rotates by means of a motor and its reciprocating motion is provided
by the hydraulic system.

 The Plastic granules are to be poured into the hopper and they will be passed through the
chamber due to the rotation of the screw.

 The Heater heats the granules to their critical temperature.

 The thermoplastic molten liquid is pressurized (by the hydraulic system) outside the Assembly
and allowed to travel through a nozzle of small diameter(Dn)[injector] with high velocity and
low pressure into the space between the molds.
  The liquid will fill the mold with uniform compaction among the atoms and thereby density is
uniform.

 After filling the liquid in the mold, by the cooling process, it will be solidified.

 Any shape and any size of the component can be produced with uniform density.

 Density can be controlled by varying the pressure in the pressure line and thereby production
rate is high and wastage is recyclable.

 The component can be produced any number of times till it achieves the required shape.

Note:

 The thermoplastic molten liquid has low viscosity and thereby it can flow easily.

 In the case of thermoset liquids, the viscosity is high and thereby it is difficult to flow from the
nozzle and that's the reason, thermoplastics will be used in Injection Moulding Machine.

Injection Molding Defects:

The defects of Injection Molding are as follows.

 Flash

 Short Shots

 Vacuum Voids

 Sink Marks

 Burn Marks

 Weld Lines

 Surface Delamination

 Warping

 Jetting

 Flow Lines

Flash:
When some of the molten plastic escapes from the mold cavity then the defect arises called
Flash.
Short Shot:
When the molten plastic does not completely fill the mold cavity due to any of the reasons, then
there will be a shortage of molding called a Short shot.
Vacuum Voids:
Vacuum voids are caused due to the uneven solidification between the inner section and surface
of the prototype.
Sink Marks:
In Injection molded products, when the shrinkage occurs in the inner portions then small
depressions develop in thicker regions called Sink marks.
Burn Marks:
Burn marks are rust-colored and can appear on the surface of Injection molded components.
Weld Lines:
Weld lines can appear on the components when the molten plastics meet each other as they are
flowing from two different parts of the mold.
Surface Delamination:
Delamination is nothing but peeled off. It is a condition where thin surface layers appear on the
component due to contaminant material. These thin surface layers appear like coatings and can
be delaminated i.e. peeled off.
Warping:
In different parts of the mold component, when the shrinkage is uneven then it is called warping.
Jetting:
Due to the difference in speed of the injection of molten metal, the molten plastic sticks to the
mold surface only, and this is a failure of not completely solidifying in the mold cavity.
This is the explanation for the defects of the Injection Molding Process.
Injection Moulding Process Advantages:
The advantages of Injection Moulding Process are as follows.
 The design flexibility of plastics is very high and it acts as an advantage to the
manufacturers to create various products irrespective of design.
 The scrap is almost zero in this type of machine.
 The color of the products can be managed during the creation of components.
 high production rate.
 Different products can be manufactured by changing the dies of mold.
Injection Moulding Process Disadvantages:
The disadvantages of Injection Molding Process are as follows.
 The machine cost and the tool cost are high.
 The cost for the creation of molds is also higher.
 Larger and complex shapes of the components are difficult to produce with uniform
density.
 Difficult to insert metal pieces in the plastic part during the production of the component.
Injection Moulding Process Applications:
The applications of the Injection Moulding Process are as follows.
 Kitchen Products
 Agriculture Products
 Plastic plates
 Industrial Pump Impeller
 Water Cooler Parts
 Medical Products
BLOW MOULDING
 Blow molding is the forming of a hollow object by inflating or blowing a
thermoplastic molten tube called a “parison” in the shape of a mold
cavity. The process consists of extruding or “dropping” a parison on
which female mold halves are closed. The female mold halves contain
the shape of the product to be produced.
What are the 4 stages of blow molding?

Although there are considerable differences in the process available for blow molding,
the basic steps are the same: (1) melt the plastic; (2) form the molten plastic into a
parison (a tubelike shape of molten plastic); (3) seal the ends of the parison except for
one area through which the blowing air can enter; (4) ...

What is the purpose of blow molding?

Blow moulding plastics is a manufacturing process that uses air blown into a mould
cavity to create a hollow component. It is commonly used to make parts for the
construction, industrial, automotive, medical and packaging sectors, among others.

What are the three main types of blow molding process?

There are three types of blow molding processes:
 Injection Blow Molding. In injection blow molding, a blow or core rod is used throughout
the process. ...
 Extrusion Blow Molding. Extrusion blow molding can be continuous or intermittent. ...
 Injection Stretch Blow Molding.
 What materials are used in blow molding?
 Blow Molding Materials
In addition to HDPE blow molding, some of our most commonly recommended
 and requested materials and finishes include: Polypropylene (PP) Polyethylene
(HDPE, MDPE, LDPE) Nylon (PA)
Extrusion Blow Molding (EBM) is commonly used to make
bottles, industrial containers, automotive products, appliance
components, and children' toys. Injection Blow Molding (IBM) is
normally used to make smaller bottles (usually smaller than 16oz
/ 500ml in volume) with high production volumes.08-Mar-2020

CALENDERING

Calendering is a speciality process for high-volume, high quality

plastic film and sheet, mainly used for PVC as well as for certain other
modified thermoplastics. The melted polymer is subject to heat and
pressure in an extruder and formed into sheet or film by calendering
rolls.
Calendering is a speciality process for high-volume, high quality plastic film and
sheet, mainly used for PVC as well as for certain other modified thermoplastics.
The melted polymer is subject to heat and pressure in an extruder and formed
into sheet or film by calendering rolls. The temperature and speed of the rolls
influences the properties of the film.
Calendering allows speciality surface treatments of the film or sheet such as
embossing or enhancing the physical properties or in-line lamination
Introduction
Calendering is a continuous process where melted plastic, paper, rubber or fabrics are squeezed
between pairs of rollers. Calendering is one method of making plastic sheets and plastic film. (Another
method is Blown Film)
Plastics Used
The plastics used to create film and sheets by calendering are:
 polyvinyl chloride (PVC)
 modified polyethylene (PE),
 polypropylene (PP)
 acrylonitrile-butadiene-styrene (ABS)
 thermosetting compounds
Making Plastic Film and Plastic Sheets
Plastic film and thicker sheets of plastic may be made by calendering molten plastic.
In the calendering process, molten plastic is extruded and then passed between pairs of heated rollers
that squeeze the molten plastic into a sheet. The thickness of the plastic sheet depends upon the gap
between the pairs of rollers. Very thin plastic sheet is called plastic film.
The calendering process usually involves using four or more pairs of rollers that gradually reduce the
plastic thickness, polish the surface, add a texture or emboss a pattern into the plastic sheet. After the
sheet passes between the final pair of rollers, it is cooled and fed to a winding station where it is coiled
and edge trimmed.
Plastic laminates and plastic/fabric laminates are also produced by calendering.
 Plastic films may be laminated, i.e. bonded, by squeezing the plastic films between pairs of
heated rollers under great pressure.
 Fabrics may be bonded to plastic film by squeezing the two materials together between pairs of
heated rollers under great pressure.
 Two fabrics may be bonded by passing one of the fabrics through a tank of adhesive and then
passing the two fabrics between pairs of rollers that squeeze the fabrics together under great
pressure.

calendering, process of smoothing and compressing a material (notably paper) during

production by passing a single continuous sheet through a number of pairs of heated rolls. The
rolls in combination are called calenders.
Materials commonly processed by calendaring equipment includes polyvinyl chloride (PVC),
woven and specialty fabrics, and high-quality paper. With plastics, heated rollers squeeze films
or sheets to produce materials that have a glossy finish.
What are the advantages of calendering?
Advantages of Calendering Process

Better control of film / sheet thickness. The properties are more uniform across the
width of the product. Better optical properties due to cooling chilled rolls. PVC being
heat sensitive material, it is safer by calendering process than extrusion process.