Strategies For Successful

Design and
Processing of Plastic Parts

1
 Introduction
to
Plastic Materials,
Properties & Applications

2
Pre requisite of world
Knowledge
class moulding
Of Plastic
Materials
Reliable Excellent
Molding Part Design
Machine
World
class
Robust
moulding
Mold Design
Optimum
Process
Parameters
Methodical
Mold Manufacture
Internally consistent & mutually supportive
3
Thorough
Knowledge Excellent
Of Plastic Part Design
Materials
Robust
Successful
Mold Design
Injection
Moldings
Methodical
Optimum
Mold Manufacture
Process
Parameters “Internally
consistent &
mutually
Reliable
supportive”
Molding Machine
4
Classification
of
Polymers

5
 Polymer

Semi
Natural Synthetic
Synthetic
Shellac Butyl Cellulose
Rubber Derivatives

6
 Polymerization

monomers

Polymer
chain

Polymer Chains

7
Monomer Molecules in Random Motion

8
Types of polymerization

 Addition polymerization

 Condensation polymerization

9
 Addition Polymerization
(Chain Growth)
 Reaction of unsaturated monomers which links to form a
continuously increasing chain

 Initiation step is slow, Propagation & Termination Steps

are Rapid

 Monomer Concentration decreases continuously during

reaction

 Increased reaction time has no effect on avg. molecular

weight or chain length

E.g. Polyethylene, Polypropylene, Polyvinyl Chloride,

Polystyrene
10
 Addition
Polymerization

Polymerization of Ethylene into Polyethylene

n = Degree of polymerization

11
 Polymer
 Macro-Molecule (3D)
12
 Condensation Polymerization
(Step Growth)
 Reaction of polymers containing specific functional
groups that undergo condensation to a lager molecule with
the release of H2O,HCl,ROH

 Concentration of monomers decrease rapidly,

Concentration of polymer increases gradually.

E.g. Polyesters, Polyurethanes, Polyamides,

Polycarbonates

13
 Catalyst
INPUT OUTPUT
1.Monomers Polymer +
2.Heat Polymerization (water/

3.Pressure Alcohol etc)

Polymerization Process

14
# PARTICULARS POLYMERIZATION
ADDITION CONDENSATION

1 Type of Reaction to Simple Addition Condensation

Frequency

Frequency
create chemical
linkages between
monomers

Molecular Weight

2 Byproduct - Water

3 Example PE,PP Polyamide,

Polyester

15
Polymerization Reactor

16
Classification
of
Polymers
with Examples

17
 Plastics

Thermo Thermo set

Elastomers
Plastics Plastics

Semi
Amorphous
Crystalline
•PC •PA •PF
•PS •PE •MF PU

•PVC •PP •UF

18
 Load , Temperature

Super
Plastics

Engineering
Plastics

Commodity
Plastics
19
 Load , Temp. & Cost

Cost
Pressure Temp.
Super /Kg.
Plastics

PTFE, PEEK,LCP
110 MPa 200° C Rs.1000
Engineering
Plastics
PA,POM,PC,ABS
60 MPa 85°C Rs.150
Commodity Plastics
PE,PP,PS,PVC
23 MPa 35°C Rs.50

20
 Difference between thermoplastic
and thermoset
# PARTICULARS THERMOPLASTICS THERMOSETS

1 Linking of Monomers Long linear chains Cross linked

(with side branches) (3D)
without cross linking
2 On application of Heat Soften to from a Gel like soft
viscous melt structure

3 Change on heating Physical Chemical

(Insoluble,
Infusible)
4 Analogy (Example) Ice, Water, Steam Egg & Omelet

5 Recycling Yes No

21
Thermoplastics:

1. Become soft when heated

2. Easily moulded
3. Remolded without significant degrading

22 22
Thermosets

1. Rigid plastics
2. Resistant to higher temperatures than
thermoplastics
3. Once set cannot be remolded

23 23
 Elastomers

1.Loosly cross linked compared to thermosets

2.More elastic than thermosets
3.Once shaped cannot be reshaped

24 24
Thermoplastics: Thermosets
Remolded without Once set cannot be
significant degrading remolded

25
n = DOP
H.D.S
> 3000

L.D Solid n > 1000

Wax 26 < n < 50

Oil 12 < n < 14

Liquid 5<n<8

Gas n = 1

Effect of ‘n’ value on State of Polymer

26 26
Injection Molding grade of Polymers
500 < n > 35,000

DOP Mechanical Melting Viscosity Processabilty

(n) Properties Point

27 27
 Amorphous Semi Crystalline
Thermoplastics
Branched Chain Linear Chain
molecules molecules

Structures of Amorphous & Crystalline Thermoplastics

28
 Amorphous

(a-morphous = without shape)

 Polymer chains in random arrangement
 Molecular structure incapable of forming regular
order (= not crystallized)
 Molecular arrangement randomly twisted, kinked &
coiled
Amorphous

Random order

29
Crystalline

 Polymer chains form a regular pattern

 Molecular structure forms regular order (crystals)
Regularly stacked in crystal-like fashion

Semi Crystalline Amorphous

(randum)

Crystalline
(Orderly)

30
 Comparison between amorphous and
crystalline thermoplastics
# PARTICULARS THERMOPLASTICS

AMORPHOUS CRYSTALLINE
1 Order of Structure Random Aligned &
Closely packed
2 Volumetric Shrinkage Less More
3 Transparency Yes No
4 Melt temperature, Melt Less High
viscosity, Shrinkage
5 Toughness & Flexibility More Less
6 Strength in direction of ~Equal in all Higher*
molecules directions
7 Ease of Processing Easy Difficult
8 Example ABS, PC, PMMA, *PP, PE, Nylon
PS, PVC

31
 Comparison between amorphous and
crystalline thermoplastics
# PARTICULARS THERMOPLASTICS
AMORPHOUS CRYSTALLINE
9 Softening with Over a broad range Sharp Melting Point
temperature of temperature

10 Bonding with Easy Difficult

Adhesives / Solvents
11 Stress cracking Prone to Resistant

12 Fatigue Resistance Poor Good

13 Typical Applications Structural only Structural +

14 Bearing / wear No Yes

applications

32
 Deformation Behaviour of Amorphous
Thermoplastics with Temperature
Tensile strength

Temperature
Tg –Glass Transition Temp. T f – Flow Temp. Td–Degradation Temp.
33
 Rigid Thermo
Thermo Plastic
Brittle Tg Elastic Tm
Tensile strength

Temperature

Tg –Glass Transition Temp. Tm –Melting Point Temp. Td–Degradation Temp.

34
 Range of Mechanical Properties
for Several Plastics
TOUGH

ABS NYLON

P.CARBONATE POLYACETAL
POLYPROPYLENE PVC

DAP POLYETHYLENE

PHENOLIC ACRYLIC
EPOXY
POLYESTER
POLYSTYRENE

BRITTLE
Position of plastic can be changed by Additives, Fillers, Reinforcements & Alloying

35
Major Families of Plastics & Their Properties

36
37
Name of Elastomer?

38
 Elastomer Material: Butyl Rubber

Composition (CH2 –C(CH3)-CH-(CH2)2-C(CH3)2)n

 Synthetic
 Resembling natural rubber in properties
 Resistant to abrasion, Tearing
 Low Gas permeability*
 Useful properties up to 1500 C
 Low dielectric constant & Loss making
them attractive for electrical applications

39
Applications -- Butyl Rubber
 Car Tyres
 Seals
 Belts
 Anti-vibration Mounts
 Electrical insulation
 Tubing
 Rubber Lining for Pipes
 Pumps

40
Identify the Elastomer?

41
Composition (CO –NH-R-NH-CO-O-R-O)n

Please write whether PU is an Elastomer or

Thermoset Plastic or Thermoplastic-plastic?

42
 Elastomer Material: PU

 Soft, Stretchy material & fabric

 Available in all grades of
thermoplastic, elastomers & thermo set
materials
 Easily foamed with a blowing agent
 Open cell / closed cell, micro-cellular,
Filter grades with varying Hardnesses
 Strongest of elastomers

43
Application of PU:
Cushions
Packaging
Shoe soles
Fuel hoses
Gears
Bearings
Car Bumpers
Adhesives
Fabric coating

44
 Thermoplastics

Guess & write the total Number of Plastics

commercially available

45
15 in Alphabetical Order

46
47
48
Guess what could be this Plastic

49
Acrylonitrile Butadiene
Styrene (ABS)

 Tough, Resilient & Easily Molded

 Can be given vivid colors
 ABS-PVC Alloy > ABS
 Weather resistant
 Can be painted

50
Acrylonitrile Butadiene Styrene
(ABS)

Composition (CH2 –CH-C6H4)n

 Tough, Resilient, Easily

Molded
 Can be given vivid colors Scooty Panels?
 ABS-PVC Alloy > ABS

51
Applications - ABS:
ABS-PVC in Power Tool Casings
 Safety Helmets
 Car Interior components Business
machines
 Wheel Covers
 Boat Hulls
 Weather Seals
 FDA Approved?

52
Please identify the Polymer

53
Material: Polymethyl-Methacrylate
(Acrylic, PMMA)

Composition (CH3 –CH2-C-CO-OCH3)n

 Thermoplastic that most closely resembles Glass in
transparency
 Resistant to weathering
 Discovered in 1872; First
commercialized in 1933
 First Major Application as cockpit canopies for
fighter aircraft during II World War

54
Application of Acrylic, PMMA :

 Lenses of all types

 Aircraft windows
 Signs
 Domestic Baths
 Electrical components
 Tool Handles

55
 Application of Acrylic, PMMA :

 Tool Handles
 Safety Spectacles
 Automotive tail Lights
 Chairs
 Contact Lenses
 Advertising Signs

56
Source: Article “The Intraocular Lens has revolutionized
Cataract Surgery. A Look at how it came about” By
Dr.J.Agarwal

After WWII, many pilots had pieces of plastic from the

windshields of their bombers embedded in their eyes.
These pieces were inert & did not cause any reaction.
One visionary British Doctor Dr.Harold Ridley wondered if
these pieces could be shaped like a lens & inserted into the
eye in cataract surgery. On Nov.24, 1949 he implanted the
first IOL in a 45 year old woman.

57
SPI identification codes

58
Thermoset Plastics

59
Advantages for thermosets:

1.High thermal stability

2.Resistance to creep & deformation under load
3.High dimensional stability
4.High rigidity ,
5.High hardness
6.Light weight
7.Excellent electrical insulating properties
8.Low cost

60
61
62
Please identify the application & guess the name of
the Polymer used
Write your answer

63
Material: Phenolics
 Commercialized in 1909 triggering a revolution
in Product Design
 Fairly strong
 Can take colors to a certain extent
 Quick & economical Replacement for Ivory
 Stiff, chemically stable
 Good electrical properties

64
Material: Phenolics
 Fire resistant
 Good Insulators
 Resist Heat & chemical attack exceptionally well
 Easy to mold
 Low in cost

65
Applications of Phenolics
 Electrical Parts like Switches, Sockets Connectors, Relays
 General Industrial Applications
 Water lubricated bearings
 Brake Pistons
 Micro-wave cookware

66
Applications of Phenolics

 Handles
 Coatings
 Adhesives
 Sandwich structures
 Good choice for Distributor cap shown

67
General Properties
of
Plastics

68
Plastics are much lighter than metals. Agreed?
Density of Plastics ?
Metals Density Plastics Density
Gm/ cc Gm/ cc
Gold 19.3 PTFE 2.1
Silver 10.5 POM (Acetal) 1.4
Copper 8.9 PC / CA 1.2
Iron / Steel 7.85 Acrylic / Nylon 1.15
Aluminium 2.7 ABS / PS 1.05
Magnesium 1.74 HDPE --- LDPE 0.96 -- 0.92
PP 0.90

69
Plastics are much lighter than metals

Which metal competes with Plastics?

70
Transparent package with excellent impact
strength is mouldable out of Acrylic

71
 TRANSPARENCY %

GLASS 90

PMMA 92

PC 89

87 88 89 90 91 92 93

72
 Optical Properties

Transparency Translucency Opacity

73
New Toy using Cellulose propionate having high impact strength, clarity and
economy can be moulded

74
Intricate shapes of components with excellent mechanical,
chemical and electrical properties can be moulded

75
Fan Blade & Blower Wheel moulded
out of mineral filled Nylon

Dynamically
stressed
(Moderate)
parts

76
 High
Strength
to Weight
Ratio

Dunnage Tray --- HDPE

Weight --- 13.5 Kg –
can carry pay load – 2.75 Tons

77
 Temperature
Resistance

Moulded Bakery Tray

Material : Glass reinforced PP
Less weight. problem - Sticking of
baked items to Tray avoided

78
Packaging applications :-
Thermoformed Egg Cartons from
Foamed extruded Polystyrene sheet

79
 Sandwich
Structure
Solid Solid
Skin Skin

Foamed Enlarged Photo of ‘Sandwich

Core moulded’ product

80
 Concrete Shutter Trough

Foamed
Solid PP Core
PP Skin

Concrete Shutter Trough with solid

Polypropylene skin and Foamed PP core

Favorable Stiffness to weight Ratio

81
 Multi-color / Multi-Polymer capability

Sandwich Moulding machine -- Clamping capacity 1500 Tons.

82
 Easy Formability of Intricate Shapes

Acrylic Sink HIPS Decorative Panel

HIPS Drawer

Thermoformed Products : --- a) Acrylic Sink b) HIPS drawer

c) HIPS Decorative Panel d) Wood-grained Plastic skin
Laminated to chip Wood base

*Wood-grained Plastic skin laminated to chip wood base

83
 Finish ability

Sailboat hull formed out of ABS

sheet & filled with expanded
Polystyrene for buoyancy

84
THERMOFORMED PARTS

85
THERMOFORMED PARTS

86
 Easy Processabilty

Removing ABS Boat-hull

with PS foam floatation
from Press

87
 Easy
Assemblabilty

Tool & Tote Box vacuum formed

of Polyethylene

88
 Platability

Blow moulded Acetal

copolymer aerosol container

89
Rotationally moulded Poly Ethylene Hobby Horse

90
 Light Weight &
Durability

Stylish Ladies Boots Slush

moulded from Plastisol --- Semi
rigid heels & soles Flexible uppers
with expandable sides & Foam liner

91
Bucket Seat with rotation
molded HDPE Structural
Shell

92
93
94
Aesthetic Appeal

95
Barbie Dolls

96
 Roto-molded
Play Balls out of
Plastisol

Rotomoulded Vinyl Ball -

Rotation moulded from Plastisol

97
E.g. Casserole

98
Seamless Nylon Fuel Tank
for Boats Characterized by

1.Light weight
2.Corrosion Resistance
3.Low Permeation Treatment

99
Cast Polyester - Chair back

100
 GFR Epoxy Mold

8.3 meter Long weighing 2.75 Kg. (can withstand 2050C)

101
 Electrical Conductivity of Different Materials Ohm/ mm2

COPPER 58.5

ALUMINIUM 38.5

STEEL 5.6

PLASTIC

0 20 40 60 80
PLASTIC STEEL ALUMINIUM COPPER
Series1 10-15 5.6 38.5 58.5

102
Non conductive Reinforced
Plastic Ladders & Platforms
protect linemen constructing
HT Transmission lines

103
 Very small to Very
Large Parts

Mould for 75 Feet Reinforced

Plastic Yacht

104
 Tub Shower

Telephone Booth?

105
 IMD?

In-mould Decoration of
Compression moulded Phenolic
Handles and inserts

106
 IMD

In mould Decoration of Injection

moulded Polystyrene cannisters

107
Automotive Applications:
 A.C Fan
 Oil Suction Tube
 Thrust Washer
 Oil Seal
 Switch Housing
 Bush Bearing………..

What mind can imagine….!

108
 THERMAL CONDUCTIVITY OF MATERIALS
W/mK

COPPER

ALUMINIUM

STEEL
0.15 - 0.5
PLASTIC
0.05
AIR

0 100 200 300 400 500

Insulators ……………………Conductors

109
Reason for low thermal conductivity of Plastics?
Advantage of poor λ?
Disadvantage of poor λ?

110
Reason for low thermal conductivity of Plastics?
 Absence of free mobile electrons
Advantage of poor λ?
 Heat insulating Handles for utensils
Disadvantage of poor λ?
 Heat required for processing can only be slowly
introduced & it is difficult to dissipate the heat upon
completion of processing

111
Thank You
112