Plastic Injection Technology

Plastics
- comes from the Greek word Plastikos meaning to form.
- material that can be heated and molded so that it keeps its molded shape after it cools.
- materials that can be reshaped (remolded) by applying heat and pressure.
- most plastics are made from synthetic resins (polymers) through the industrial process of
polymerization
- recycling is the major advantage in plastics to reduce the waste

Why use of Plastics?

Plastics are easily formed materials.
The advantage to the manufacturer is that plastic products can be mass-produced and requires less
skilled staff.
Plastics require little or no finishing, painting, polishing, etc. Plastic is referred to as a self-finishing
material. Particular finishes can be achieved at relatively low cost.
Plastics can be easily printed, decorated or painted.
Plastics are corrosion resistant and generally waterproof although certain type of plastics such as UPVC
can become brittle and its possible for the suns rays to cause the color of the plastic to fade. It
becomes bleached.
Plastics are lighter than metals, giving deeper sections for a given weight, and hence stronger sections.

Synthetic Plastics
The main source of synthetic plastics is crude oil.
Coal and natural gas are also used.
Petrol, paraffin, lubricating oils and high petroleum gases are bi-products, produced during the
refining of crude oil.
These gases are broken down into monomers. Monomers are chemical substances consisting of a
single molecule.
A process called Polymerisation occurs when thousands of monomers are linked together. The
compounds formed as called polymers.
Combining the element carbon with one or more other elements such as oxygen, hydrogen, chlorine,
fluorine and nitrogen makes most polymers.

Natural Plastics
Natural plastic products occur in such things as animals horns, animals milk, insects, plants and
trees.
Animal horns - Casein (glue)
Animal milk - Formaldehyde (glue)
Insects - Shellac (French polishing)
 Plants - Cellulose (table tennis balls), Cellulose acetate (cloth, photographic film, handles), Cellophane
(wrapping), Bitumen (roads, flat roofs)
Trees - Latex (rubber)

Classification of Plastic Polymers

1. Thermoplastic
There are a wide range of thermoplastics,
some that are rigid and some that are extremely
flexible.
The molecules of thermoplastics are in lines or long
chains with very few entanglements. When heat is
applied the molecules move apart, which increases
the distance between them, causing them to
become untangled. This allows them to become
soft when heated so that they can be bent into all
sorts of shapes.
When they are left to cool the chains of molecules
cool, take their former position and the plastic becomes stiff and hard again. The process of heating, shaping,
reheating and reforming can be repeated many times.

2. Thermosetting Plastics
The molecules of thermosetting plastics are
heavily cross-linked. They form a rigid molecular
structure.
The molecules in thermosets sit end-to-end and side-
by-side.
Although they soften when heated the first time,
which allows them to be shaped they become
permanently stiff and solid and cannot be reshaped.
Thermosets remain rigid and non-flexible even at
high temperatures. Polyester resin and urea
formaldehyde are examples of thermosetting
plastics.

Comparison Between Thermoplastics and Thermosetting

 Thermoplastic Resin Types
Abbreviation Common Name Main Usage
Cups, dish, containers, tooth brush grip, electronics
PS (GPPS/HIPS) Polystyrene
casing, packaging cushion
PMMA Polymethyl Methacrylate Tail lamps, false eye, billboards, windshield, lenses
ABS Acrylonitrile, Butadiene, Styrene Electric parts, electronic parts, auto parts, helmets
Gears, bushing, compact disks, lens for glasses,
PC Polycarbonate
electronic parts
Film, sheets, synthetic leather, hoses, pipes, plastic
PVC (Soft / Hard) Polyvinyl Chloride
curtains
PBT Polybutylene Terapthalate Auto parts, air con fins
High heat resistant connectors, coil bobbin, contact lens
PES Polyethersulfon
container
Buckets & pails, washtubs, container lids, plastic bags &
PE (LDPE/HDPE) Polyethylene
sheets, bottle caps
Tablewares, containers, pails, battery case, auto parts,
PP Polypropylene
house wares, monoblocks
Gears, bushings, rollers, caster wheels, zipper,
PA Polyamide (Nylon)
connectors, threads
Connectors, motor parts, breakers, fuse, oven parts,
PPS Polyphenylene Sulfide
autoparts
PETE Polyethylene Terephthalate Containers, plastic bottles
Pump components, autoparts, appliance pars, gears,
POM Polyoxymethelene (Polyacetal)
knobs
V Vinyl Clear food packaging, shampoo bottles

Thermosetting Plastic
Abbreviation Common Name Main Usage
PF Phenol Wiring equipment, telephone, ash trays, pot handles
UF Urea Socket, teacups, caps, mahjong tiles
MF Melamine High-end table wares, ornamental plates, formica
laminates
UP Unsaturated Polyester Buttons, automobile parts, helmets, roofing materials
PDAP Dialuric Terephthalate Transistors, resistors and other electronic components
SI Silicon Underwater motor parts, release agents
Alkyd Paint material
ARYLICS (PMMA)
a. strength
- availability of all ranges of optical transparency, including opacity - heat resistance
- surface hardness - rigidity
- it is half the weight of the glass
b. limitations
- grain effect - limited chemical resistance
- discolor with high UV exposure - poor wear and abrasion resistance
- attacked by organic solvents - low impact strength
c. applications
- protective glazing - toys
- windows - point of purchase (POP) displays

POLYSTYRENE (PS)
a. strengths
- inexpensive - easy to bond
- quick to bond - easy to decorate
b. limitations
- low impact resistance - brittle after UV exposure
- cant be used at elevated temp. - mechanical stress
c. applications
- refrigeration - disposable beverage glass
- medical devices - disposable laboratory products
- wood replacement products

POLYVINYL CHLORIDE
a. strengths
- low cost - good chemical resistance - good strength
- versatile - naturally UV resistant
b. limitations
- heat sensitive - low impact strength - poor wear resistance
c. applications
- pipe, valves & fittings - point of purchase displays - packaging
- pollution control equipment parts - thermoformed parts for transportation, exhibits & machinery
SEMI-CRYSTALLINE COMMODITY PLASTICS
a. key characteristics
- low cost, strength and temp. resistance - excellent chemical resistance
- low COF - near zero moisture absorption
- very good electrical properties - good toughness
b. materials
- polyethylene (PE) HDPE, LDPE
- polypropylene (PP)
- polymethylpentene
Polyethylene (PE), Polypropylene (PP), Polymethylpentene
Partially crystalline, partially amorphous
Largest family are the polyolefins
Cost, benefits and limitations are different for each

POLYETHYLENE (PE)
a. key characteristic
- classified by density and molecular weight - excellent chemical resistance
- zero moisture absorption - light weight (1/8 weight of steel)
- excellent insulator - low COF
- high impact strength
b. applications
- packaging - wire and cable - industrial

LOW DENSITY POLYETHYLENE (LDPE)

a. key characteristic
- good chemical resistance - very flexible
- high impact strength - low heat resistance (60 to 79C/140 to 175F)
- used extensively in packaging industry and for prosthetic devices

HIGH DENSITY POLYETHYLENE (HDPE)

a. key characteristics
- higher rigidity and tensile strength than low and medium density polyethylenes
- good formability
- slightly lower impact strength than LDPE
- virgin grades are FDA and USDA approved

LDPE & HDPE Applications

- films - liners - marine industry - bathrooms and pipes
- industrial trash bags - shipping bags - playgrounds - automotive
 POLYPROPYLENE (PP)
a. key characteristics
- excellent chemical resistant - excellent fatigue strength
- lower impact strength than polyethylenes
- available in homopolymer and copolymer
- copolymer offers better impact, clarity and cold temperature properties
b. applications
- packaging - automotive - consumer/durable goods
- vacuum formed parts - fiber/carpet

POLYETHYLENE TEREPHTHALATE (PET)

a. strengths
- optical transparency - good toughness - ability to sterilize
- easy to fabricate - easy to form
b. limitations
- limited UV resistance - cant be used above 60 to 66C (140 to 150F) range
- low softening point precludes sterilization
c. applications
- packaging - graphic arts -point of purchase (POP) display

Reasons for Using Filler, Fiber, Additive and Blend

Certain plastic products are created in such a way so that they possess specific properties and qualities
depending upon where and how the product will be used.
Particular products need have mechanical properties. They may need to be hard, strong and have a high
resistance to impact.
Other products need to possess certain environmental properties. They may need to have a resistance to
chemicals such as acids and alkalis.
Plastics used outside may need to have a high resistance to ultra violet light and be flame resistant. For
some it may be important that they do not absorb water.
Before the raw materials can be converted into finished products they need other substances added in
order to give the required properties.
Fillers, Fibers, Additives, Blends
Fillers Fibers Additives Blends
Glass spheres Glass Fibers UV Stabilizer ABS / PVC
Carbon black Carbon fibers Plasticizer PC / ABS
Metal powders Aramid fibers Lubricants PBT / PC
Silicon sand Jute Flame retardant EPDM / PP
Wood flour Nylon fibers Colorants
Ceramic powders Polyester fibers Antistatic
Mica flakes Antioxidants
Molybdenum Disulfide Processing aids
Preservatives
Fungicides
 Smoke suppressant
Foaming agents
Viscosity modifier
Impact modifier

Blends are mechanical mixture of chemically different polymers or copolymers

Expectations about Blends
High performance at reasonable price.
Modification of performance as market develops.
Extending the performance of expensive resins.
Generation of unique materials.
They should be economical, competitive and should not affect other needed properties.
They should be easy to process.

PLASTIC MATERIAL SELECTION

o Identify application requirements - mechanical (load, impact, stiffness, etc.), thermal (temperature range,
maximum use temperature, etc.), environmental considerations
o Identify the chemical environment - define the chemical stress, temperature, contact time and type
o Identify specific loads - regulatory (UL, FDA, etc.), outdoor or UV exposure, light transmission (clear or
opaque), fatigue and creep requirements
o Define processing considerations - Injection molding, blow molding, extrusion, thermoforming, foam
molding etc.
o Assembly - painting, plating, shielding, adhesion, snap fit, welding etc.
o Finish & gloss, cost and availability