Plastic has revolutionized the entire human dynasty, and as a result of which plastic products are all around us. Products, manufactured from plastic, are durable and lightweight. Further, they possess high resistance to wear, impact and corrosion. Almost every second product in our surroundings, including mobile phones, water bottle, laptops, keyboard, credit cards, etc. are made from plastic and honestly, it is frightening to imagine a day without them. However, the question arises, how are different products manufactured from plastic?
The process of plastic product manufacturing totally depends on the type of product one wants to develop. Here are the 5 most common manufacturing processes utilized to develop a custom product from plastic:
Rotational molding is a process normally used to create different types of hollow items. During the process, the finely ground plastic resin is heated in molds, which are whirled on two axis while being warmed in huge ovens. Centrifugal force, on the other hand, propels the melted plastic alongside the walls of the mold. During the entire heating phase, the mold rotates continuously, at all times, to maintain even thickness and to avoid deformation or sagging, during the cooling phase. Various products such as fuel tanks, children’s play balls and kayaks (boats) are developed using this process.
Rotational molding provides tool designers the freedom to produce molds that comprise curves, inserts, and contours, along with company logos and openings for plastic or metal supplements to be placed. Manufacturing costs with rotational molding are lower than injection molding and blow molding.
If you are planning to develop products from thermoplastic or thermosetting plastic, then injection molding is the best process for you. Molten plastic is introduced at a great pressure into a molds that is the opposite of the preferred shape. The mold is stored locked under extreme pressure and condensed so that the product hardens. Once the plastic solidifies, the mold is released, normally automatically, and the final product is achieved. The mold is prepared from metal (aluminum or steel) and accurate-machined to meet the characteristics of the wished part.
Injection molding is normally used to manufacture plastic products, including bottle caps, locomotive dashboards, wire spools and many other plastic products offered in today’s market. It is the most common process for plastic product manufacturing. It is suitable for manufacturing high quantities of the similar object. There are many advantages of injection molding, including repeatable high tolerance, impressive production ratio, the potential to use different range of materials and inexpensive labor cost.
Blow molding is a new product developing process used to produce hollow plastic parts. Generally, blow molding are to three different types, including stretch blow molding, extrusion blow molding, and injection blow molding.
During the blow molding process, plastic particles are introduced into a hopper and then warmed to form molten plastic. After proper heating, the material (molten plastic) is blown into the form of the mold. As soon as, the material (Plastic) is condensed and cemented the mold releases, and the part is driven out. The blow molding procedure is generally used to develop products such as plastic drums, bottles, fuel tanks, etc. This process is affordable than injection molding, however costlier than rotational molding. As a drawback, the manufacturing procedure is normally limited to hollow forms.
In this process, melted plastic is extruded through a die that offers the correct profile shape. This process is employed to develop products with a steady cross-section. Normal plastic products in your surroundings are made from this process include rain gutters, PVC pipe, straws, etc. Compared to other manufacturing processes, it is relatively low cost and affordable.
Thermoforming is new product manufacturing process typically used for warming and casting temperature-sensitive material. It makes use of a wide range of molds and procedures in order to reach the end-product. A thin-gauge thermoforming is commonly used for manufacturing disposable cups, lids, blisters, trays, containers and many other products for food and common retail businesses. On the other hand, thick-gauge thermoforming is used to develop parts such as refrigerator liners, vehicle door, plastic pallets, vehicle dash panels, and utility vehicle beds.