The document discusses various topics related to plastics manufacturing including: 1. Types of plastics and their characteristics as well as common shaping processes like injection molding, compression molding, and blow molding. 2. Key industrial applications of thermoplastics processing including blow molding, rotational molding, film blowing, extrusion, and thermoforming. 3. Differences between thermoplastics and thermosetting plastics in terms of their molecular structure and ability to be remelted and reshaped.

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)
Hydrogen peroxide

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
*Calendering process is used for sheet making.
*A calender is a series of hard pressure rollers used to form or
smooth a sheet of material such as paper or plastic film.
*thickness of the sheet is controlled by combination of squeezing
and altering the speed of rolls.

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
Laminations:
• It is done by the applications of heat and pressure. It
consist of layers such as paper, cellulose, glass fiber etc.
• thermoplastics are bonded by the process of lamination.
• the pressure applied is 7MPa and temperature about 150
C

25. The methods of joining plastics
and composites:
 Mechanical fastening
Uses of additional parts such as metallic screws,
bolts, washers, rivets.
 Adhesive and solvent bonding
Adhesive is placed between parts to be bonded
where it serves as the material that joins the parts and
transmits the load through the joint.
 Welding or fusion bonding.

26. YoucaN

27. Friction bonding or friction
welding
 Friction welding of PVC tubes and pipes is well
developed. Prior to welding process, the ends of the
tubes are sized by heating the tube ends oil to 100 C for
3 to 4 minutes and then tube are clamped in gauge for
3 minutes followed by water cooling to room
temperature.

28. Ultrasonic welding
 Process in which mechanical vibrations of high
frequency are used. The frequency range from 15 to 20
kHz.
 Transducer which converts high frequency energy
supplied by ultrasonic oscillator into vibrations.
 It is possible to weld acetyl, nylon nd high density
polyethylene, PVC