Plastics are synthetically produced non-metallic compounds.

It can be molded into various forms and hardened for commercial use. Plastic molding products can be seen everywhere. Examples are jars, protective caps, plastic tubes, grips, toys, bottles, cases, accessories, kitchen utensils and a lot more. Even the keyboard and the mouse that you use are made through plastic molding. Even the plastic parts of the chair that you are sitting on are created this way. The basic idea in plastic molding is inserting molten liquid plastic into a ready shaped mold, for example the mold of a bottle. It will be then allowed to cool, then the mold will be removed to reveal the plastic bottle. Plastic molding can also custom-mold a wide variety of plastic products including: garden pots, cabinets, office trays and boxes, barriers, barricades and traffic signage and displays for product and marketing promotions. If you are planning to go into plastic molding business, you should first know the different processes. Choose from a plastic molding process that fits your budget, your expertise, and your resources. Here are basic definitions of various methods of plastic molding. The Plastic Molding Processes: Injection Molding In Injection Molding, melted plastic is forced into a mold cavity. Once cooled, the mold can be removed. This plastic molding process is commonly used in mass-production or prototyping of a product. Injection molding machines were made in the 1930s. These can be used to mass produce toys, kitchen utensils, bottle caps, and cell phone stands to name a few. Blow Molding Blow molding is like injection molding except that hot liquid plastic pours out of a barrel vertically in a molten tube. The mold closes on it and forces it outward to conform to the inside shape of the mold. When it is cooled, the hollow part is formed. Examples of blow molding products are bottles, tubes and containers. Equipments needed in setting-up a blow molding business are relatively higher than injection molding. Compression Molding In this type of plastic molding, a slug of hard plastic is pressed between two heated mold halves. Compression molding usually uses vertical presses instead of the horizontal presses used for injection and blow molding. The parts formed are then air-cooled. Prices of equipments used for compression molding are moderate.

Film Insert Molding This plastic molding technique imbeds an image beneath the surface of a molded part. A material like film or fabric is inserted into a mold. Plastic is then injected. Gas Assist Molding Also called gas injection molding is used to create plastic parts with hollow interiors. Partial shot of plastic is then followed by high-pressure gas to fill the mold cavity with plastic. Rotational Molding Hollow molds packed with powdered plastic are secured to pipe-like spokes that extend from a central hub. The molds rotate on separate axes at once. The hub swings the whole mold to a closed furnace room causing the powder to melt and stick to the insides of the tools. As the molds turn slowly, the tools move into a cooling room. Here, sprayed water causes the plastic to harden into a hollow part. In this type of plastic molding, tooling costs are low and piece prices are high. Cycle time takes about 40-45 minutes. Structural Foam Molding Structural foam molding is a process of plastic molding usually used for parts that require thicker walls than standard injection molding. Inserting a small amount of nitrogen or chemical blow agent into the plastic material makes the walls thicker. Foaming happens as the melted plastic material enters the mold cavity. A thin plastic skin forms and solidifies in the mold wall. This type of plastic molding can be used with any thermoplastic that can be injection molded. Thermoforming In this plastic molding process, sheets of pre-extruded rigid plastics are horizontally heated and sucked down into hollow one-piece tools. When the hot plastic solidifies, its shape conforms to that of the mold. Tooling costs are usually low and piece prices vary on the machinery. Plastic molding is a very technical process. It needs experts in this type of manufacturing business for it to be competitive in the market. Therefore, a very scientific and systematic study should be first made before going into this endeavor.

Many people are confused by the different moulding processes. To help you understand and decide the most appropriate method for your application, each process will be explained here. Please note: Rutland Plastics is an Injection Moulder and does not provide any other moulding services. Below is a brief description of the processes to be covered together with typical applications. In time links will be added to pages providing more information on each process. Blow Moulding This covers a range of different processes: Blown Film Extrusion of polymer through a circular die. Then expanded into tube for packaging. Either bags, sacks or sliced to form sheet. Extrusion Blow Moulding Molten polymer is extruded into a pipe shape. The mould closes around a set length and this tube is then inflated. This method is used for bottles. Injection Blow Moulding This is the most common method for high volume. Generally used for bottles and jars. Superior visual and dimensional properties to extrusion blow moulding. Injection Stretch Blow Moulding Similar to injection blow moulding but the plastic is stretched as well as blown into shape. Used for high quality containers. Extrusion Plastic granules are melted and fed through a die to form the shape. Unlike injection moulding which produces individual parts, this is a continuous process. Used for pipes, curtain tracks, window profiles and plastic sheet. Can be cut to shorter lengths as required. Rotational Moulding Also know as Rotomoulding or Rotamoulding. Used for hollow plastic products. The polymer is placed in the mould in its powder form. The mould is rotated around two axis in an oven spreading molten plastic around the mould. Typical products include tanks, childrens large toys such as slides and playhouses, canoes and pallets. Vacuum Forming Plastic sheet is heated until soft and then draped over a mould. A vacuum is applied to suck the sheet into the mould to form the shape. Typical products include baths and shower trays, refrigerator linings and yoghurt pots. Thermoforming is similar but air pressure and other assistance may be applied to the sheet. Faster cycle times than for vacuum forming. The largest application is food packaging. Reaction Injection Moulding (RIM) Also known as structural foam moulding. Two materials are combined and placed into a mould. The chemical reaction causes the material to expand and fill the mould. Some finishing to the parts is required, including painting. Typical applications include business machine housings and decorative wood effects.

Dip Moulding Mandrels are dipped into a bath of plastic paste or fluidised powder to produce a peelable skin. Typical applications include protective gloves, handle grips and balloons. Compression Moulding Moulding of thermosets. The powder is compressed and heated in a mould to produce a precision part. Typical applications include fuse boxes, saucepan handles and insulators. Pultrusion - Extrusion process with materials composed of a polymer and high performance fibre, such as glass. Used for solid or hollow profiles in demanding environments such as aerospace, building and civil engineering applications.