The document discusses various topics related to plastics manufacturing including types of plastics, polymerization processes, properties of plastics, types of resins, thermoplastics vs thermosetting plastics, and common shaping processes for plastics like injection moulding, blow moulding, rotational moulding, extrusion, compression moulding and transfer moulding. Key plastic shaping processes are injection moulding using ram or screw machines, blow moulding, rotational moulding, film blowing, sheet making and extrusion. Common applications of thermosets include compression moulding and transfer moulding.

1. MANUFACTURING OF PLASTIC COMPONENTS
Types of plastics - Characteristics of the forming and shaping processes –
Moulding of Thermoplastics – Working principles and typical applications
of - Injection moulding – Plunger and screw machines – Compression
moulding, Transfer moulding – Typical industrial applications –
Introduction to Blow moulding – Rotational moulding – Film blowing –
Extrusion - Thermoforming, - Bonding of Thermoplastics.

2. ORGANIC MATERIALS
Natural – Wood, Coal, Petroleum &
Natural Rubber
Synthetic – Plastics, Synthetic rubber,
Ceramics & Glass
Organic material - Polymers

3. Polymers
Poly means ‘Many’ & ‘Mers’ means
‘Parts’
Polymer built of several repeating
units(Monomer)
Monomer – small molecules
Polymer is made up of thousands of
monomers jointed together to form
large molecule.
Plastics – Organic polymer

4. Polymerization process
A Polymer is made up of linking
thousands of monomer and thus obtaining
large molecule is called Polymerization
process
Additives – Plasticizers (liquid form) –
Water, Organic solvents & resins
Catalyst – Promote faster & complete
Polymerization
Dyes – Impart desired colour
Initiators – Initiate the reaction (H2O2)

5. Plastics
Can be moulded into required shape
with the help of pressure or heat or
both heat and pressure
Resin – liquid form of plastics, also raw
material for making plastics
Types of resin: acrylic resin,
Polyethylene resin & amino resin –
Produced by polymerization process
Catalysts, Binders & Lubricants added
with resin to form plastics

6. Modifiers – To improve the mechanical
properties of plastics
Lubricants – To reduce friction during processing
, Avoid sticking to mould walls(Oils, Soaps and
waxes)
Solvents – Dissolve fillers or Plasticizers & Allow
the processing in fluid state(Alcohol)
Fillers – Mica, Cloth fiber
Elastomers – To enhance the elastic properties

7. Properties of Plastics
Elongation
Heat resistance
High rigidity
Surface hardness
High viscosity
Density
Chemical resistance

8. Thermosetting Plastics
Thermosetting - Plastics which are hardened by
heat effecting non reversible chemical change .
Molecules are formed by condensation
polymerization process.
All the molecules have three dimensional
network and very strong binding force between
molecules
Bakelite, Polyester resin, Epoxy resin(Araldite),
Silicones, Urea formaldehyde(Amino resin) &
Alkyds

9. Thermo Plastics
Have separate long and large size molecule arranged
side by side
When thermoplastics are heated it becomes very soft
and rehardens on cooling
During heating the linear bonding links between
molecules are breakup and separated. Relinking takes
place on cooling and retains their hardness.
Cellulose nitrate – pen bodies, Table tennis balls,
Frames
Ethyl cellulose – Jigs, Fixtures, hose nozzles
Cellulose acetate - Radio cabinets, steering wheels,
Insulating tapes

10. Synthetic resins
Polyethylene – Fabrics, tray, pipes, tubing chemical
containers & corrosion resistant coatings
 Polystyrene - Battery boxes, radio parts, toys
Vinyles(PVC) – Tarpaulin, Water roofing, raincoats, tubes
Polytetra fluroethylene (Teflon)- Gaskets, Greaseless
bearing, Electrical insulators, Chemical containers
Polyamide(Nylon) – Gears, wire insulation, combs,
Bearings and couplings

11. S.
No
Thermoplastics Thermosetting plastics
1 Softened by heating Cannot be softened by
heating
2 Structure is made of linear
chain molecule
Structure is made of cross-
linked molecule
3 Produced by addition
polymerization process
Produced by condensation
polymerization process
4 Can be reproduced by
heating and cooling
Cannot be reproduced
5 When the temp increases
the plasticity also
increases
Plasticity is stable at high
temperature
6 Softer and less strong Harder and strong
7 Scrap can be reused Scrap can not be reused

12. INJECTION MOULDING
1) RAM OR PLUNGER TYPE INJECTION MOULDING

13. THERMOPLASTICS - INJECTION MOULDING
2) SCREW TYPE INJECTION MOULDING

14. THERMOPLASTICS – INDUSTRIAL APPLICATION
2) BLOW MOULDING

15. THERMOPLASTICS – INDUSTRIAL APPLICATION
3) ROTATIONAL MOULDING

16. THERMOPLASTICS – INDUSTRIAL APPLICATION
4) FILM BLOWING

17. THERMOPLASTICS – INDUSTRIAL APPLICATION
5) SHEET MAKING

18. THERMOPLASTICS – INDUSTRIAL APPLICATION
6) EXTRUSION PROCESS

19. THERMOPLASTICS – INDUSTRIAL APPLICATION
7) VACUUM FORMING PROCESS ( THERMO FORMING)

22. THERMOSETS
1) COMPRESSION MOULDING

23. THERMOSETS
2) TRANSFER MOULDING

24. BONDING OF THERMOPLASTICS

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