lesson 3

5
Process Advantages Once process settings are finalized, process can operate automatically with minimal human labor, except for secondary finishing. Process is capable of extremely complex shapes, although this must be balanced against higher tooling costs and more complicated operation and maintenance.

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Page 1: Lesson 3

� Process Advantages◦ Once process settings are finalized, process can operate automatically with minimal human labor, except for secondary finishing.

◦ Process is capable of extremely complex shapes, although this must be balanced against higher tooling costs and more complicated operation and maintenance.

Page 2: Lesson 3

� Process Advantages◦ Because of the high pressures involved, process is capable of reproducing an excellent – even mirror surface finish, depending on finish on tooling.

Page 3: Lesson 3

� Process Disadvantages◦ Compared to other plastics processes, tooling costs are high.

◦ Some part details, such as undercuts, are not easy to construct in the mold.

◦ Parts with high levels of residual stresses can continue to shrink or warp for several days after molding.

Page 4: Lesson 3

� Process Disadvantages◦ It can take a long time to build the molds because of the tighter tolerances and making sure that the mold can withstand the high pressures that are needed for the process.

◦ It is hard to predict accurate shrinkage. Depending on how the part is processed, the shrinkage can be changed. The process has a huge effect on the parts final dimensions.

Page 5: Lesson 3

� Competing Processes◦ Except for large parts, hollow parts can be assembled from several injection molded parts.

� The traditional hollow parts processes are Blow Molding, Rotational Molding, and Twin-Sheet Thermoforming.

◦ Injection molding can make equivalent parts at higher tolerances, assuming volumes justify higher tooling and extra assembly costs, and aesthetic standards will allow a welded area around the part.