PRESSURE MOLDING &

VACCUM MOLDING
Presented by
Patel Rutik R.
Roll no:201
1. Compression molding
What is compression molding?
▸ Compression molding is one of several molding processes. It is
the use of compression (force) and heat to shape a raw material.
▸ Compression molding is the process of molding in which a
preheated material is placed into an open, heated mold cavity.
The mold is then closed with a top plug and compressed in order
to have the material contact all areas of the mold.

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MATERIAL

▸ Thermosetting polymers
▸ Fiber reinforced plastic
▸ Thermoplastic

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Process SEQUENCE
▸ Charge is placed in cavity of matched mold in
the open position.
▸ Mold is closed by bring the two halves
together.
▸ Pressure is exerted to squeeze the material
so that it fills the mold cavity.
▸ While under pressure the mold is heated
which cures the material.
▸ The component is ejected from the mold and
any excess material formed at edges(flash)
is removed.

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PROCESS SEQUENCE

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Stage in compression molding cycle
▸ The various stages of the
compression molding cycle time can
be represented as a function of the
force required to close the mold at a
constant rate.
▸ The first stage is the “plastication”
stage in which the force increases
rapidly as the polymer feed is
compressed & heated.

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▸ In the second stage flow commences, once the yield
stress of the elastomer is exceeded.
▸ Here, tc is the time at which the mold fills &
compression of the melt occurs.
▸ Ideally to aid mold filling the majority of the chemical
reaction should take place after tc .

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TYPES OF COMPRESSION MOLDING
1. Sheet molding compound (SMC)
▹ Sheet Molding Compound (SMC) is a compression molding compound often used for larger
parts where higher mechanical strength is needed.
▹ Thermoset Sheet Molding Compound (SMC) is a mixture of polymer resin, inert fillers, fiber
reinforcement, catalysts, pigments and stabilizers, release agents, and thickeners
▹ Manufacture of sheet molding compounds is a continuous in-line process .

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2. Bulk molding compound (BMC)
▹ Bulk Molding Compound (BMC) is a thermoset plastic
resin blend of various inert fillers, fiber reinforcement,
catalysts, stabilizers, and pigments .
▹ In this process the charge, is placed in the bottom half
of a heated matched metal mold. The mold is closed to
compress, spread and finally cure the material.

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advantages

▸ Cost efficient
▸ Suitable for high volume production
▸ Dimensional accuracy
▸ Capable of producing large components
▸ Efficient in material usage – wastage is minimal
▸ Physically quick and efficient with a low number of
process steps
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disadvantage

▸ Curing time large

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Application
▸ Dinnerware like plates, bowls are made of
melamine by compression molding process.
▸ Handles of utensils like cookers, pans are made
using CM process.
▸ Television, telephone housings.
▸ Radio housings.
▸ Electrical parts like switches, switch boards,
insulators.
▸ Body and interior panels of cars, vans, etc.

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2. Vacuum molding
▸ Vacuum molding, sometimes referred to as vacuum
forming.
▸ It is one of the type of the thermoforming process in
which vacuum is used to get the desired shape.
▸ Vacuum forming is a manufacturing method used to shape
plastic materials. During the vacuum forming process, a
sheet of plastic is heated and then pulled around a single
mold using suction.

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▸ Vacuum forming is used for a wide range of manufacturing
applications, ranging from small custom parts produced
on desktop devices to large parts manufactured on
automated industrial machinery.
▸ Vacuum forming is the simplest type of plastic
thermoforming, that uses one mold and vacuum pressure
to obtain the desired part geometry.
▸ It is ideal for parts that only need to be precisely formed
on one side, such as contoured packaging for food or
electronics.

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How does vacuum forming work? Heat
source Plastic
sheet

The step-by-step vacuum forming process

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▸ Once the thermoplastic sheet is softened
enough (reaches a plastic state) then plate
is raised to bringing the mould into contact
with the plastic.
▸ Trapped air remaining between the mold
and the heated plastic sheet is then
evacuated by a vacuum pump.
▸ Atmospheric pressure acting over the top
surface completes the forming process by
pressing the plastic sheet onto the mold.

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▸ Once the plastic has been formed around/into
the mold, it needs to cool. For larger pieces,
fans and/or cool mist are sometimes used to
speed up this step in the production cycle.
▸ After the plastic has cooled, it can be removed
from the mold and released from the
framework.
▸ The completed part will need to be cut out of
the excess material, and edges may need to be
trimmed, sanded, or smoothed.

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BENEFITS
▸ Particularly for smaller production runs vacuum forming is
typically more affordable than other manufacturing methods,
such as plastic injection molding.
▸ Production time for vacuum forming tooling is typically half as
long as the amount of time required to produce tooling for
injection molding.
▸ Molds can be made out of wood, aluminum, structural foam, or
3D printed plastics, so they can be changed out and/or modified
more easily compared to other manufacturing processes.

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LIMITATION
▸ Vacuum forming is only viable for parts with relatively thin walls
and simple geometries.
▸ The finished parts may not have a consistent wall thickness, and
concave parts with a deep draw are difficult to produce using
vacuum forming.
▸ It is often the most cost-effective choice for small to mid-range
production quantities, other plastic manufacturing
processes can be more affordable for very large production
runs.

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APPLICATION
▸ In cars, everything from bumpers to floor
mats, and even truck beds, are
manufactured using vacuum forming.
▸ It is used to produce many industrial
crates and contoured containers for
machinery.
▸ Razors, toothbrushes, electronics,
makeup, and cleaning products often
come in packaging that was vacuum
formed.

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APPLICATION
▸ Fruit containers, plastic egg cartons and cracker
trays are often vacuum formed.
▸ Children’s toys, travel accessories, and home decor,
all are made using vacuum forming.

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Thank you

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