Compression Molding-What to Know
Molding is increasingly becoming common in productions that have high volumes. While there are other methods of molding like injection molding and transfer molding, this article will look at compression molding. In this molding process, plastic materials are placed into a heated metal mold, it is then put under heat pressure to get softened and finally forced to conform to the mold’s shape as the mold closes.
The rubber compression molding process begins with taking rubber compound that has been made to match the shape and weight of the end product. The rubber is injected into a heated mold and to close the mold, a top force is needed. Once the mold has been closed, the material that has been poured goes through some compression by pressing between the plates and causes it to fill the cavity. To activate the cure system, the material is held in the mold and high temperatures and pressures maintained to activate the cure system. After the exerted pressure and heat until the optimal time is reached, the material will have finally attained the expected shape and hence it is allowed to cool.
Due to the high-pressure, high-volume nature of the compression molding, it is a most suitable process for molding high-strength fiberglass reinforcements. Additionally, compression molding can be used in molding advanced composite thermoplastics. Before molding the Advanced composite thermoplastics are preheated to reduce the chances of excess flash.
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In compression molding, there are three major compression types; the straight plunger-type, the landed plunger and the flash plunger. All the mentioned types hold a broad size range. This method of molding is commonly used in the manufacture of electrical parts, buckles, radio cases, appliance housing, gears, buttons, e.t.c
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Why Compression Molding is Beneficial
Tooling is less complex and the cost of construction is lower. It has a less percentage of scrape material as compared to transfer molding or traditional injection.
It is possible to compress mold from most elastomers. Compression molding requires that one is careful to note a number of things before embarking on the process.
Ensure that you determine the right amount of material.
Ensure that you know the minimum amount of heat required for heating the materials. The minimum heat required should always be determined. Ensure that you have conned the best heating technique.
Predict the amount of force required so as to ensure that the shots attain the proper shape.
Design the mold for fast cooling after the compression of the material into the mold.
Compression molding has a setback in that it is difficult to control flashing and the product consistency is poor. When compared to injection molding, it produces fewer knit lines and a small amount of fiber-length degradation is noticed.