There are different plastic manufacturing processes. Many people aren’t aware of the processes and differences between each. Plastic extrusion, injection molding, and vacuum casting – the list of processes goes on. Each of the methods requires different step-by-step instructions.
Here’s a quick post that highlights different methods and the differences. Manufacturing plastic products is a long-drawn process, dive into the article to understand the different processes.
The Most Common Methods of Manufacturing Plastic and the Differences
There are different methods of manufacturing plastic. The most common methods are the following –
- Injection molding
- Blow molding
- Vacuum casting
- Plastic extrusion
- Rotational molding
- Thermoforming
- Compression molding
- Injection molding – A hopper is used for feeding the plastic polymer into a screw and heated barrel. The screw then melts the plastic and inserts or injects the polymer (liquid) into a split mold tool. This is how the shape is created. In case of high-volume manufacturing, this method is used. One can use this method to make bins and vehicle bumpers.
- Injection blow molding – The method is similar to injection molding and plastic extrusion. However, the air pressure forces the plastic to expand in the extrusion shape or mold. The interior of this object remains hollow. This particular process is utilized for making affordable containers like beakers, bottles, and cups.
- Vacuum casting – The method is used for making small plastic parts (functional). It is ideal for low-volume production. Vacuum casting is a versatile technology and is used when air entrapment becomes a problem. A vacuum is used to draw in liquid material into the mold. The procedure is used for fast production of end-use products and prototypes.
- Plastic extrusion – Pellets or plastic powder are fed into an extrusion mechanism using a hopper. The polymer is then heated within a barrel. The temperature is controlled after which a screw pushes the plastic (molten) through a die. This is then cooled to give the plastic a final shape. The plastic extrusion process is most commonly used for high-volume production. It is used for manufacturing construction products such as window and door frames, pipes, seals, etc.
- Rotational molding – Rotational molding is a good method for manufacturing hollow plastic items. The procedure goes as follows – a plastic polymer is placed inside the mold before the heating process. The closed mold then enters into a furnace and starts rotating. Now, this rotation allows the plastic polymer to evenly coat the inside of the mold. The mold needs to cool down till the resin gets hard and takes shape. This process is best for making complex and large shapes such as crates, bins, cooler boxes, canoes, bollards, and toys.
- Thermoforming – You might have seen eggs, fresh meat, and fresh fruits being packaged in thermoformed plastic trays or containers. As for the process of making plastic products out of this method- a thermoplastic sheet is heated to its softening point. The sheet is then stretched on a single-sided mold. Once this is done, the mold is manipulated and left to cool down.
- Compression molding – Car tires, rubber tires, automotive parts, and electric components are made using compression molding methods. A measure amount of the molding material is preheated and then compressed into the desired shape or form using heated molds (two of them).
Choosing the Right Kind of Manufacturing Method
All of the above procedures are different from each other. Your choice in manufacturing process really depends on the type of product you need as well as the volume. Now that you are aware of the differences, it will be easier for you to choose the appropriate process.
When choosing the manufacturing process, you have to keep the following aspects in mind:
- Product characteristics – Does your product have a high tolerance requirement? Manufacturing procedures will be limited if your product is complicated to make.
- Material – Ask for the available choices. You might want to consider the functionality and aesthetics here.
- Volume and cost – What is the exact volume of products you require? Is it high-volume or low-volume? Low-volume manufacturing is a little more expensive than high-volume manufacturing.
- Time to produce – How much time will it take to manufacture the plastic products? You need to ask the manufacturer about the timeframe. High-volume production might take several months to complete, but you must be aware of the estimated time frame.
Once you share the specifications with the manufacturer, it will be easier for them to offer their expert advice as well. Pangea Technologies is happy to offer our insights as you work through your designs and consider different manufacturing processes.
Some manufacturing processes take 24 hours for production, others can take some more time. High-volume production would certainly take more time in total than low-volume production.
Choosing the manufacturing method will now be easier for you. Make sure you compare the differences and ask as many questions as possible before getting started.