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Packing:
Allow the flasks to cool to room temperature and paint all surfaces.
EXCEPT THE TEETH, with tin foil substitute until shiny.
Prepare a mix of acrylic resin sufficient for a denture (30 gr. polymer to
30 cc monomer is enough for the average case). Follow manufacturers'
directions for proper mixing and packing consistency. See dental
materials section at the end for characteristics of polymerization.
(a)MuCell
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and licensed by Trexel Inc., is called MuCell (µCell). Further physical
foaming methods are Optiform (Sulzer Chemtech) and Ergozell (Demag
Ergotech).
The critical point is the highest temperature and pressure at which a substance
can exist as a vapor and liquid in equilibrium. A gas above its critical
temperature becomes a supercritical fluid. Carbon dioxide at about 1100 psi
or nitrogen at about 750psi become supercritical and dissolve into the polymer
melt. As molding pressure decreases, the gas undissolves from the polymer to
form a uniform cellular structure. Such foams have cell sizes ranging from 5 -
100 microns and exhibit excellent mechanical properties and can provide
thermal and acoustic insulation.
• Reduced weight
• Improved flowability
• Lower apparent viscosity
• Less warpage, shrinkage and molded-in stress
• Improved cycle time
• Reduced clamping force
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(b)Multi-Component Molding
Two-shot injection molding allows the first material to cool before the second
one is injected. Critical variables such as draft and mold temperature must be
considered when using either of these processes.
Combining hard polymers with soft materials in a 2-shot molding process can
enable new functions:
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• Haptic elements on hard surfaces
• Inject damping elements
• New designs (such as complicated gaskets) are made possible
• Balance tolerances
Processing Considerations
Machine/Mold:
Tool Designs:
There are also several types of tool designs such as:
• Core Back - A sliding core is first closed and Melt 1 is injected, then
the sliding core is opened and Melt 2 is injected.
• Rotating Plate - This two-station tool rotates in a vertical or horizontal
direction for the injection of Melts 1 and 2.
• Index - The mold is physically transferred from one point to another.
In addition to the tool design, one should also consider the wall thickness, the
surface structure of the part from Shot #1 (for venting problems), the tool
surface and temperature (for demolding), the gating location (for adhesion in
dependence of flow path), the kind of contact (flat or overflow), and how the
part will be demolded (force in the adhesion area).
Materials:
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Process Variables:
• Use the recommended molding conditions for each material at the outset
and then refine them if necessary (molding conditions can vary widely
between materials).
• The resin having the highest melting point or glass transition
temperature should normally be “shot” first
• It is often desirable to preheat parts to be overmolded to achieve better
adhesion
• Coating parts to be overmolded occasionally can be useful to achieve
better adhesion.
• NEVER try to use multi-shot regrind unless it has been thoroughly
studied (as severe degradation could occur).
• Other processing variables that should be studied are the melt
temperatures of the two materials, the tool temperature, the injection
speed, the hold pressure, screw retraction, and air traps
Testing:
Multicomponent parts should be tested at temperatures above those expected
in end-use and exposed to thermocycling to expose any problems with
expansion/contraction. The tests should also rule out any antagonistic
relationships between the two resins.
In general, the minimum amount of resin, gas injection time and gas pressure
necessary to produce a good part should be used. Gating should be designed
to facilitate melt flow and gas entry points should allow the gas to flow in the
same direction as the resin. The gas injection point leaves a hole in the part
and so may need to be located in an inconspicuous location. Gas channels
should be cut steel safe until the tool has been sampled and the process is
optimized.
6-Blow Molding
Many of Acrylic resins are capable of being processed via blow molding, and
are used in such applications as: small fuel tanks for lawn care tools, fuel
floats, chemically resistant containers, HVAC or coolant ducts, multilayer
structures, and pharmaceutical containers.
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( c)Injection Blow Molding:
A two-step process in which a preform is molded and kept in a near-molten
condition. It is then indexed into another mold and blown into a finished part.
Parison programming can also be used to vary the wall thickness over the
length of the part or to maintain a uniform wall thickness for a complex part
with areas of high blow up ratio.
Material Requirements
• Good melt strength (high zero shear rate viscosity & low melt index)
• Good melt stability (retention of molecular weight at processing
temperatures)
• Reasonable “blow ratio” capabilities
• Good weldline strength
Most resins can be accommodated using injection blow molding, whereas the
stretch blow molding process demands a high viscosity at the processing
temperatures.
7-Compression Molding
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Thermoplastic resins may be loaded into the mold either in the form of pellets
or sheet, or the mold may be loaded from a plasticating extruder.
Thermoplastic materials are heated above their melting points, formed and
cooled. For both thermosets and thermoplastics, the better the feed material is
distributed over the mold surface, the less flow orientation occurs during the
compression step.
8-Rotational Molding
Lower viscosity resins are typically used in this process as they are more
readily sintered to ensure a good surface finish. The material must be capable
of being ground into a 35-mesh powder that flows like a liquid. It must also
be able to adhere to the hot surface of the cavity and fuse together without
pressure. The material should be stabilized to resist oxidation, or a nitrogen
purge must be used during processing.
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Process Steps
9-Thermoforming
REFRENCES
[1] http://www.ticona.com/homepage
[2] http://www.plasticmoulding.ca/techniques.htm
[3] http://www.epa.gov/ttn/uatw/hlthef/methylme.html
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