Lesson 3 Extrusion Blow Molding

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Extrusion Blow Molding
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Introduction
Extrusion Blow Molding is a process that can
create hollow parts. There are two different
industry segments that use Extrusion Blow
Molding, packaging (bottles) and industrial (any
parts that are not bottles).
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To Read
Review Chapter 6.4.3 and 6.4.3.1 before beginning
the lesson.
To Do
Take Quiz 8 after this lesson and before
scheduling Exam #3.
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Topics
What is Extrusion Blow Molding
Continuous and Intermittent Extrusion Blow
Molding
3D Blow Molding
Common Materials and Key Processing
Parameters
Advantages and Disadvantages of Extrusion Blow
Molding
Competing Processes and Future Development
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Introduction
Extrusion blow molding is a process that can make
small to large hollow parts quickly.
The products range from less than 1 oz up to 1000
gal
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Some current products:

Containers
Gas Tanks
Toys
Seat Backs
Air Ducts
55 gal Drums
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The process starts with the formation of a

hollow tube of plastic, called a parison.
The tube is extruded downward until it extends
past the bottom of the mold.
The mold then closes on the parison..
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Air is introduced into the parison via a blow

pin at the top of the part or a needle in the
middle of the part, inflating the plastic and
pushing it against the mold sides.
The part cools in the mold.
The part is ejected from mold.
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Continuous Extrusion Blow Molding

The parison is continuously extruded
throughout the cycle.
It can only be used with materials that have
good melt strength.
It also can only be used for short cycle times.
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Intermittent Extrusion Blow Molding

The plastic material that is extruded is stored in
an accumulator.
When the mold opens, the accumulator
pushes the material out of the die to form a
parison.
It is used for parts with long cycles and
materials with low melt strength.
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3D
It is used for parts with complicated tubular
geometry.
It is used with intermittent extrusion blow
molding.
Can be used with multiple materials (CoExtrusion).
Usually an elastic material with a rigid material.
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There are two ways to get air into the parison.

Blow pins are used to bring the air in on the
parting line of the mold.
In bottles, it is inserted through the neck.
Blowing needles are used to create very small

holes in a part. Such pins can be located
anywhere in a mold.
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The plastic material expands through its

thickness as it exits the die. This is called die
swell.
It expands because of plastic memory. The plastic
material is squeezed as it goes though the land in
a blow molding die.
As it exits, it wants to go back to the shape it had
before it went through the land.
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During the formation of the Parison, it gets

longer and heavier. As it gets heavier, gravity
starts to extend the Parison. This is called
Parison Sag.
This creates an uneven wall thickness in the
Parison.
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Materials with High Melt Strength are needed

in Extrusion Blow Molding to reduce the
amount of Sag (and excess thinning) in the
Parison.
Lower barrel temperatures than Injection Molding
are used to increase viscosity.
Wide Spec/Higher Molecular Weight grades are
used to give the parison more strength to hang
without tearing or excessive sagging.
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Common Materials
Olefins (Polyethylene, Polypropylene)
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Common Materials
Thermoplastic Elastomers (TPEs)
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Common Materials
Polycarbonate
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Common Materials
PVC
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Key Processing Parameters

Melt Temperature Changes the viscosity of the
material.
Extruder Speed Determines the speed that the
parison is made.
Blow Time Although blowing forms the product,
holding the pressure on the product keeps it in
contact with the mold and increases the cooling.
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Key Processing Parameters

Blow Pressure Helps to pick up surface detail in
the mold.
Parison Drop Time How long the parison hangs
and stretches before the mold closes.
Parison Programming Creates local thickness
changes in the parison.
If the parison is off-center, it will cause thickness
variation around the circumference of the part.
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Process Advantages
Molds are inexpensive vs. injection molding. Since
molding pressures are much lower, tooling can be
produced in aluminum.
Irregular geometry can be easily molded if the
mold can open without destroying the part.
There is the ability to combine several
components into one part.
The inside volume of the part can be filled with
foam while the mold is still closed.
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Process Advantages - Co-extrusion

By using specialized polymers, better barrier
properties can be had.
Recycled materials can be layered in the middle.
Less costly materials can be used in a layer to
reduce the parts cost.
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Process Disadvantages
There are problems filling corners and deep
sections because the parison will be stretched
too thin.
In injection molding, the part is cooled and
constrained by two sides of the mold. With
extrusion blow molding, the part only touches
the mold on one side. This helps to create
wider tolerance than is seen with injection
molding.
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On long flat surfaces there is a tendency for the
flat surfaces to warp.
To ensure proper filling and a strong weldline, the
parison is extruded larger than the tool. Hence,
there is always some flash created as excess
material is squeezed between parting lines during
the blowing operation.
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Secondary operations are always needed to
remove flash. Holes and other features are put in
after the part is removed from the mold.
There is wall thickness variation because of
parison sag and part shape. The parts tend to be
thinner at the top because of sag. When the parts
have a bigger local diameter, the parts will be
thinner in the thicker regions. The further the
parison has to travel; the thinner it gets.
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Disadvantages
Any surface defect that result from the extrusion
of the parison or sweating of the mold will cause
surface appearance problems on the part.
If there is a change in parison thickness or if the
pinch-off is not designed correctly, there could be
a weak weld leading to part failure.
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Competing Processes
Injection Molding
Hollow parts can be made, but they must be molded in
halves and assembled. The parts will have constant
wall thickness and tighter tolerances.
Rotational Molding
Parts will have more uniform wall thickness, but will
have a looser tolerance.
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Competing Processes
Twin Sheet Thermoforming
Parts will have an external seam/weld.
Injection Blow Molding

Parts will not have a weld, have better surface finish,
and tighter tolerances, but cannot be produced as large
or as structural.
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Future Development
Extrusion Blow Molding is looking at converting
parts or products, that have two components that
are assembled together, to one Extrusion Blow
Molded part. Because Extrusion Blow Molding is
a hollow part process, both sides of a product can
be molded together.

Lesson 3 Extrusion Blow Molding

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Lesson 3 Extrusion Blow Molding

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Plastics 001

Extrusion Blow Molding

Extrusion Blow Molding

Some current products:

The process starts with the formation of a

Air is introduced into the parison via a blow

Continuous Extrusion Blow Molding

Intermittent Extrusion Blow Molding

There are two ways to get air into the parison.

Blowing needles are used to create very small

The plastic material expands through its

During the formation of the Parison, it gets

Materials with High Melt Strength are needed

Key Processing Parameters

Key Processing Parameters

Process Advantages - Co-extrusion

Injection Blow Molding

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