THERMOSET INJECTION MOULDING

Principle of Injection Molding of Thermosetting Resins

In thermoset injection molding, cold material is injected into an extremely hot mold. Then the material in the
mould is allowed to cure to get the product.

The thermosetting material (in granular or pellet form) suitable for injection molding is fed from the hopper into
the barrel and is then moved forward by the rotation of the screw. During its passage, the material receives
conductive heat from the wall of the heated barrel and frictional heat from the rotation of the screw. The
material thus accumulate in front of the screw is then injected into the mould. Finally the part is cured inside the
mould and ejected.

THERMOSET INJECTION MOULDING

 THERMOSET INJECTION MOULDING
A Thermoset injection molding press consists of two major sections:
1. The clamp and
2. The injection unit.
• The clamping section, which is similar to a compression press, uses either a hydraulic clamp or toggle clamp to close the mold halves
and hold them together under pressure.
This section of the press also contains the main ejection system for part removal from the mold.
• The injection unit includes the
•injection barrel,
•reciprocating screw or sometimes a plunger for BMC materials,
•the injection screw motor,
•the material hopper for granular materials and a stuffer when molding BMC.
• The rotational motion advances the material down the screw to where it is plasticized and then injected into the mold.
• The melt temperature of the molding material is controlled by
• the barrel temperatures,
• screw speed,
• injection speed and
• back pressure.
• To maintain a consistent melt temperature, all of these variables must be adjusted properly.
• The melt temperature cannot be too hot that the material cures before it is able to fill the parts.
• It should not be so cold that it cannot be injected into the mold or require additional cycle time to cure the molded parts.
Typical temperature range
• 165°C - 180°C for PF molding compounds,
• 150°C - 180°C for MF molding compounds,
• 150°C - 175°C for granular polyester molding compounds,
• 140°C - 170°C for BMC polyester molding compounds.

THERMOSET INJECTION MOULDING

Thermoplastic injection Thermoset injection

molding molding
1. Material is melted (Hot) Material is cold
2. Normally, Mould is cooled Mould is Heated
3. Material may be in Material may be in
granule and pellet form powder, pellet, DMC form
4. Screw root is tapered Screw root is straight
5. High L/D ratio screw (20:1) Low L/D ratio screw (5:1)
6. Barrel is electrically Barrel is water cooled or
heated oil heated
 THERMOSET INJECTION MOULDING

What are the advantages of thermoset Injection Molding process?

Easy Material handling
Parts containing metal inserts can be molded
Higher productivity
lower piece costs.

What are the disadvantages of thermoset Injection Molding process?

Parts may be more prone to warpage
Parts may have knit lines. These knit lines are usually the weakest areas of the part.
The total amount of scrap being produced during injection molding will usually be higher than
that for compression molding

THERMOSET INJECTION MOULDING

Applications
The applications of Injection-molded thermoset plastics includes
• Switch housings
• Fuse box
• Wiring device
• Electrical connector housings
• Iron box handle
• Distributor caps
• Power-tool housings
• Office machines
• Ashtrays
• Cookware handles and
• knobs
8
 GAS ASSISTED INJECTION MOULDING
Principle: Gas assisted injection moulding (GAIM or GAM) process is used to
produce hollow, lightweight plastic products. The process involves partially filling a
mould with molten polymer then injecting nitrogen gas into a mould. The gas forces
the molten plastic against the sides of the mould and holds the plastic until it cools
and solidifies.
The main two principles of
Gas Assisted Moulding are to
either inject the gas into the
component cavity (internal
gas injection), or to use the
gas on the outside surface, but
still within the mould cavity, to
consolidate the component
(external gas injection).

GAS ASSISTED INJECTION MOULDING

Processing: Polymer powder or granules
are fed into a heated injection moulding
machine
The polymer is melted in the injection
moulding machine
A measured amount of polymer is injected
into the mould
Nitrogen gas is injected into the mould so
that the gas forces the molten polymer
against the internal sides of the mould.

There are two methods of injecting

nitrogen gas, either into the molten
polymer or between the polymer and one
side of the mould.
GAS ASSISTED INJECTION MOULDING
Gas Assisted Injection Moulding (Internal Method)
Process follows this sequence of operations:
• molten polymer is injected into the mould until the
mould is about 70% full of polymer
• nitrogen gas is injected into the polymer.
• The polymer cools and solidifies as it touches the cold
sides of the mould.
• Nitrogen gas passes along the path of least resistance
which is the hot, middle part of the polymer.
• The gas forms a bubble inside the polymer and forces
the polymer against the sides of the mould.
• The gas holds the polymer tight against the sides of the
mould until it cools
• The gas is released from the mould
the mould is opened and the moulded product is ejected

GAS ASSISTED INJECTION MOULDING

Gas Assisted Injection Moulding (([ternal Method)

Process follows this sequence of operations:

•molten polymer is injected into the mould until the
mould is full of polymer
•nitrogen gas is injected under pressure between the
molten polymer and the mould. The gas forms a thin
bubble between the polymer and the mould, forcing
the polymer against the opposite side of the mould
•the gas holds the polymer tight against the sides of
the mould until it cools
•the gas is released from the mould
•the mould is opened and the moulded product is
ejected.
 GAS ASSISTED INJECTION MOULDING
Advantages:
Internal
•The polymer picks up every detail in the mould
•Less polymer is used to make the product, typically between 20% and 50% saving in
material
•Products are lighter because there is less material
•Products cost less to produce because less material is used
•Hollow parts are structurally strong and rigid due to the box section structure
•Shrinkage marks and warping are eliminated as the gas holds the polymer firmly
against the sides of the mould until it cools and solidifies.
External
•This method of gas assisted injection moulding produces mouldings that:
pick up the detail on one side of the mould only
• shrinkage marks and warping are eliminated
7

GAS ASSISTED INJECTION MOULDING

Applications
Typical products made by gas assisted injection moulding include:
•handles
•automobile trim
•automobile instrument panels and other large sheet-like structural parts with a
built-in gas-channel network
•TV cabinets
•shower heads
•plumbing fittings
•tube-like parts

Polymers typically used for gas assisted injection moulding are

Polypropylene (PP) Polyethylene (PE)

Acrylonitrile-butadiene-styrene (ABS) Polycarbonate/Acrylonitrile-butadiene-styrene (PC/ABS)
Polycarbonate (PC) Polystyrene (PS)
Polyvinyl Chloride (PVC) 8
 INTRODUCTION

TWIM or Thin wall Injection Moulding has been paid more and more attention,
especially in computer, communication and consumer electronic (3C) industries,
due to economic and environmental concerns.

The reason is that thin-wall molded parts could be made lighter, more compact,
less expensive, and quicker because of fast cooling
Thin wall plastic food containers are becoming more and more popular. The
thermoforming disposable containers are considered to cost more of electricity
power consumptions and complex process. As you know, thermoforming process
is two stages, it needs the shape forming from the plastic sheet, the plastic sheet
extrusion molding are complex too. From the
sheet being heated until the vacuum forming and deflashing…
 INTRODUCTION
Principle: TWIM or Thin wall Injection Moulding Thin wall injection
molding is a specialized form of conventional injection molding that focuses
on mass-producing plastic parts that are thin and light so that material cost
savings can be made and cycle times can be as short as possible. Shorter cycle times
means higher productivity and lower costs per part.
For packaging containers thin wall means wall thicknesses that are less than 0.025
inch (0.62mm) with a flow length to wall thickness greater than 200.
The definition of thin wall is really about the size of the part compared to its wall
thickness. For any particular plastic part, as the wall thickness reduces the harder it
is to manufacture using the injection molding process.
 STANDARD VS. THIN-WALL PROCESSING
Key Factors Conventional Thin-Wall
Typical Wall 0.080-0.120 0.050-0.080 <0.050
thickness, in.
Machinery Standard High-end Custom
Inject. Pressure, 9000-14,000 16,000-20,000 20,000-35,000
psi
Tooling Standard Better venting, Extreme venting, very
heavier heavy construction,
construction, mold interlocks,
more ejector precise surface
pins, better preparation, extensive
polish ejection features,
mold costs 30-40%
higher than standard.
Control System Standard Closed-loop on Same as at left, with
injection speed, resolution of 0.40 in.
hold pressure, on speed, 14.5 psi on
decompression pressure, 0.004 in. on
speed, screw rpm, position, 0.01 sec on
backpressure, time, 1 rpm on

THIN WALL INJECTION FLOW

4Thin wall parts require higher injection

pressure because the distance that the material
can flow is dependent on the thickness
of the part. As the following Illustration shows,
the material Forms a frozen skin on the outside
walls of the cavity first And then starts to solidify
towards the centre. The centre of the flow is the
last To solidify. If your wall section is very thin
then this solidification occurs very quickly.
4Melt streams should reach all the boundaries of
mould before melt freezes.
4Freezing time is proportional to cube of wall
thickness. Therefore, for thinner wall, melt
should flow fast enough to ensure that melt fills
fully before it freezes. Hence, max injection rate
of machine is important specification of machine
to
determine spread of melt through longest flow
 ADVANTAGES

Cheap, safe and clean plastic parts.

Allows faster cycle times compared with thicker walled plastic
parts.
Lighter parts reduce fuel emissions in automotive applications.
½ Thin wall molding reduces resource consumption and cuts
weight, reducing fuel usage and carbon emissions in shipping –
further supporting sustainability efforts.

Made from recyclable plastics such as polypropylene (PP) in

food packaging.
Some thin wall parts can be made from sustainable plastics.

LIMITATIONS

• Environmental litter.
• High capital investment cost for injection molders. Thin wall
molding requires specialized molding machines, injection
molds and robots that can withstand the high stresses, fast
cycle times and relentless 24/7 production schedules.
• To make thin wall parts we requires highly skilled molding
technicians and these are difficult to find and keep.
 APPLICATIONS
The following industries make
use of thin wall molding:

T food packaging ( eg. food containers

and lids)

Tautomotive (eg. both structural and

non-structural car parts)

T mobile telecommunications (eg.

mobile phone housings)

Tmedical (eg. syringes)

Tcomputing equipment (eg. computer

housings)

CO-INJECTION MOULDING
Principle of Co-Injection Molding

Co-injection involves a second component (core) being injected into the first
component (skin). It is used to produce parts that have a laminated structure with
the core material embedded between the layers
ayers of the skin material.
 CO-INJECTION MOULDING
Processing: As shown in figure, the process involves sequential injection of two different but
compatible polymer melts into a cavity where the materials laminate and solidify. A short shot of skin
polymer melt is first injected into the mold (Figure a), followed by core polymer melt which is injected
until the mold cavity is nearly filled (Figure b); the skin polymer is then injected again to purge the core
polymer away from the sprue (Figure c). The process offers the inherent flexibility of using the optimal
properties
roperties of each material
materir al or modifying
ri mo the properties of each materiall or those of the molded
e part.

(c)

(a) (b) (c)

FIGURE Three stages of co-injection (sandwich) molding. (a) Short shot of skin polymer melt (shown in black) is
injected into the mold; (b) injection of core polymer melt until cavity is nearly filled; and (c) skin polymer melt is
injected again, pushing the core polymer away from the sprue.

CO-INJECTION MOULDING

A The skin material is typically a standard resin (Poly olefins) while the core in a food
or beverage packaging application is typically a resin with barrier properties (EVOH)
that prevents the permeation of oxygen, carbon dioxide, or moisture through the
container walls.
An application that is looking to reduce costs or weight and/or save virgin resin would
typically use a “regrind” or recycled resin as a core with the skin material still having
the desired appearance.
Graduated color or other effects can be introduced in the core for aesthetic packaging
applications for shelf differentiation.
 CO-INJECTION MOULDING
A standard co-injection machine would have a multi-material capable injection molding
machine with two injection barrels or a mono injection molding machine with an
auxiliary injection unit for the 2nd material, a specialized hot runner system with
nozzles equipped to deliver the two separate resins from the two injection barrels, and
software for simultaneous melt stream control.
With advancements in resin and barrier layer materials, excellent clarity can still be
achieved for a clear package.

CO-INJECTION MOULDING

Benefits of coinjection:

cost reduction
• cheaper material for the core component
• ability to use recycled material
• foamed core material for lighter parts

increase of part properties

• higher mechanical strength despite high surface quality
• combination of galvanized skin – with reinforced core components
• improved part quality – fewer sink holes

marbling
 CO-INJECTION MOULDING
Applications:
Typical Food Packaging Co-injection Applications Include:
•Thinwall containers and tubs, clear or colored
•PET performs
•Caps and closures
•Dairy containers
•Single-use coffee pods/capsules
•Retortable clear plastic cans
•Medical applications – bottles, vials, etc.
•Shelf Differentiation: aesthetic packaging, color gradation

Typical Resin Saving/Regrind Applications Include:

•Small and large buckets
•(paint containers, chemical, fluids, etc.)
•Skids and shipping containers
•Large automotive parts
8

LIQUID INJECTION MOULDING

Principle:
Liquid silicone rubber injection molding is a thermoset process that cools the material
delivery system, while heating the mold tool to cure silicone material into parts.
Liquid silicone injection molded parts are elastic with a high degree of chemical,
electrical and thermal resistance. In addition, the parts are biocompatible and can be
subjected to sterilization.
 LIQUID INJECTION MOULDING
Processing: Liquid silicone rubber injection molding machine appears to look just
like thermoplastic injection molding machines. Both types of presses use the same
basic machine parts, clamp unit, and injection unit.
The silicone injection molding machines typically have a hydraulic ram and may have
a hydraulic toggle. Some presses are designed with an electric ram with toggle.
Unlike the high pressures used to mold thermoplastic parts, liquid silicone injection
pressure is in the range of 800 PSI. The purpose of the clamp is to contain the
expansion force of the silicone material by keeping the mold closed as the silicone
cures.

LIQUID INJECTION MOULDING

The injection unit for liquid silicone runs cool with a water cooled barrel and nozzle to
prevent the liquid silicone from curing. Thermoplastic injection units run the opposite
way, they need the barrel and nozzle to be heated to 200oC or more to keep the
material moving.
Liquid injection molding units also run at lower pressures (under 1,000 PSI), while
their thermoplastic counterparts run at tens of thousands of PSI.
There is a part A and Part B. Colorants come in the form of dispersions and are
normally 1-3% by weight of mixed silicone. The silicone dousing unit pumps one part
A silicone and one part B silicone via separate hoses to the static mixer.
In addition, color is pumped to the static mixer via another hose. The mixed
components are then fed into the throat of the injection molding barrel by way of a
shut-off valve.
 LIQUID INJECTION MOULDING
LIM machines include:
Injectors: These devices pressurize the liquid material.
Metering Units: In order for LIM to be successful, there's needs to be a catalyst and
a base forming silicone material. Metering units help ensure that these two materials
maintain a constant ratio while they're in the process of being released.
Supply Drums: These components, which are also commonly referred to as
"plungers," are the mixing containers.
Mixers: These combine the materials before they're injected into the designated
mold.
Nozzle: These carry out the injection into the mold.
Mold Clamp: This is what secures the mold during the production process, as well as
what opens the mold back up when the process is completed.

LIQUID INJECTION MOULDING

Once the silicone material is inside the barrel, a shot of the cool mixed silicone
advances to the mold as the nozzle seals firmly against the mold.
The nozzle shut-off valve opens and a measured shot of cool liquid silicone is injected
into a hot (275F to 390F) clamped mold.
Then the nozzle shut-off valve opens and the barrel retracts from the mold, while the
screw begins to build another measured shot of cold liquid silicone.
After the silicone vulcanizes in the heated
mold, the clamp will open and parts are
then manually removed or automatically
ejected.
Cycle times for liquid silicone molded parts
are often similar to their thermoplastic
counterparts.
 LIQUID INJECTION MOULDING
Advantages:
• Liquid silicone rubber based products have constant mechanical properties
over a wide temperature range
• Labour intensive preparation of rubber based products is eliminated by
injection moulding of LSR
• Shorter cycle time
• Shorter injection pressure
• LSR products are good
• Ozone resistant,
• UV resistant and
• Weather resistant
• They also possess excellent chemical resistance

LIQUID INJECTION MOULDING

Applications:
Typical Applications Include:
• Seals of all kinds
• O-rings,
• isolators,
• electronic components and
• Parts in the aerospace and automotive industries
• Switching mats for electrical devices
• Numerous medical parts like…

9
 INJECTION COMPRESSION MOULDING
Principle:
Injection Compression molding (ICM) is a manufacturing process combining the
techniques of both injection molding and compression molding.
Mold is not closed completely at the filling stage. After melt is partially filled into the
cavity, the clamping mechanism starts operating to fully close the mold. As a result,
the filling process is completed by the compression of cavity surface unto melt in
cavity.

INJECTION COMPRESSION MOULDING

Processing: In “injection-compression moulding“ involves the introduction of
thermoplastic polymer melt into a slightly opened mould with simultaneous or
subsequent compressing by an additional clamping stroke.
This additional clamping stroke can be accomplished via the machine or via a
compression punch in the mould.
The cavity pressure building up in the mould is distributed in two dimensions more
uniformly over the projected component surface, usually with the aim of improving the
accurate reproduction of surface detail and the dimensional stability of the
components.
 INJECTION COMPRESSION MOULDING
Processing: Injection-compression moulding processes are low-pressure processes, so as
to
• not damage inserts such as decorative film or metal inserts.
• decorative trim or metal inserts are protected.
In the case of transparent applications that low injection and follow-up pressures minimize
internal stresses and, thus, have a strong influence on the optical properties.
A suitable injection moulding machine must therefore feature not only a high degree of
flexibility, but rather also very precise and reproducible movements.

INJECTION COMPRESSION MOULDING

Advantages:
•Improvement of dimensional stability,
•elimination of sink marks and warping
•Mould filling > 100%
•Possible injection pressure and clamping force reduction
•Reduction of orientations, fibre orientation and internal stresses
•Less material shear
•Improved venting
•Less shrinkage and residual stress
•Shorter cycle time and
•reduced manufacturing cost
Disadvantages:
•Extra costs of machine and mold
•Early diagnosis of flash problem
•Not suitable for parts with great depth in the injection direction
•Complicated process condition control, such as compression time, force, speed, etc.
 INJECTION COMPRESSION MOULDING
Applications:
Typical Applications Include:
Electronics
Optical(e.g. lenses, headlamp diffusers, headlights, displays, etc.)
Automotive
Medical
Consumer Product

Continuous strand-reinforced formed parts (e.g. door modules, protective

undercoatings, etc.)
Decorated components (e.g. decorative strips, side panels, mobile phone casings,
etc.)
Components with surface textures (e.g. Fresnel textures, lotus surfaces, etc.)
Foamed components (e.g. insulating components, light-weight constructions,etc.)
Components with problem zones (e.g. formation of voids, shrink marks at the end of
the melt flow path, etc.)
7

MULTILEVEL FEED INJECTION MOULDING

Principle:
Multi-shot injection molding also known as twin-shot injection molding, is a process
where two or more colors and / or materials are injected simultaneously into a mold,
creating one or multiple components.
 MULTILEVEL FEED INJECTION MOULDING
Processing: Two-shot, also referred to as dual-shot, double-shot, multi-shot and
overmolding, is a plastic molding process in which two different plastic resins are
molded together in a single machining cycle.
Essentially, the molding process remains the same as traditional injection molding.
However, the integration of additional injection units is required.
Commonly the number of the additional injection units can range from 2 to 6, one for
each material or color.
This process is advantageous when it’s necessary to combine different material
properties into a single component.
Materials commonly used for this process include thermoplastics, thermosets
and liquid silicone rubber.
In these cases, it is essential that the materials have a common adhesive quality, this
ensures that the individual components of the final component are securely bonded.

MULTILEVEL FEED INJECTION MOULDING

Processing: There are two phases of the two-shot molding process.
1. The first is similar to traditional injection molding: A shot of resin is injected into a
mold and cooled to form a solid part.
2. In the second phase, the just-molded part is transferred to a second mold via a
rotating platen or a robotic arm, and receives the second shot of resin – in,
through or around certain parts of the first molded part, depending on the design.

The two plastic resins then form a molecular bond and the multi-resin molded part
is cooled and ejected.
 MULTILEVEL FEED INJECTION MOULDING
Advantages:
Compared to other methods of plastic molding, two-shot is ultimately a more cost-efficient way of
producing an assembly with multiple components.

Part Consolidation | Two-shot injection molding reduces the number of components in a finished
assembly, eliminating costs associated with each additional part number.

Improved Efficiency │ Two-shot molding allows multiple components to be molded with a single tool,
reducing the amount of labor needed to run your parts and eliminating the need to weld or join
components after the molding process.

Improved Quality │ Two-shot is carried out within a single tool, allowing for lower tolerances than other
molding processes, a high level of accuracy and repeatability, and reduced scrap rates.

Complex Moldings │ Two-shot injection molding allows for the creation of complex mold designs that
incorporate multiple materials for functionality that cannot be achieved through other molding processes.

MULTILEVEL FEED INJECTION MOULDING

Applications:
Typical Applications Include:
Lawn and garden, agriculture, medical, consumer, and appliance, with significant
experience in automotive.

From consumer goods to construction, two-shot molded components are used in

nearly every industry, but are most commonly found in applications requiring the
following:
•Movable segments or components
•Rigid substrates with soft grips
•Vibration or acoustic dampening
•Surface descriptions or identifications
•Multi-color or multi-material components