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Plastic Molding Process Comparison Molding Process Injection Reaction Injection Blow Vacuum Forming (vacuumforming) Compression Extrusion Rotational Thermoforming Twin Sheet Foaming Selective Lazer Sintering Rapid Prototyping Lost Foam Casting (for making molds) Process Description Ideal Purposes Heated plastic is injected into mold Plastic is injected into mold and cures from chemical reactions Panels, Enclosures, housings, automotive parts A parison (tubular plastic charge) is attached to a mold and then filled with air Heated plastic sheet is stretched over mold and suctioned into the form Product packaging, speaker casings, car dashboards, aerospace Heated plastic charge is compressed to shape of the mold Heated plastic is forced through a die creating a long part Plastic charge is placed in mold which rotates, bi-directionally, in oven Containers, fuel cells, Large/complex products, housing, enclosures, concept products Heated plastic sheet is stretched over mold Disposable cups, containers, lids, trays, blisters, clamshells, vehicle door and dash panels, refrigerator liners, utility vehicle beds, and pallets Method of Thermoforming that welds 2 plastic sheets into one 3D product Pallets, portable toilets, housings, tanks, air & ventilation ducts, enclosures, cases, toys, flat and transportation related products Plastic material is heated with a laser until its particles adhere to each other Photosensitive plastic is cured by a laser in layers Part is coated and pressed into sand. Metal (or other material) is poured into depression Creating small and/or critical tolerance parts Bottles, various containers Automotive parts, textiles, large pattern pieces Tubing, piping, fiber optics Concept or highly specific/critical tolerance designs Concept designs Making molds and duplicates of concept designs Low Mold Cost? X X X X X X N/A N/A N/A Low Unit Cost? Quick Turn Around Time? X X X X X X X X X X High Strength Parts? X X X X X Complex Part Geometries? X X X X X Pros Quick turn around and very detailed parts Low mold costs, strong flexible parts Fast, cheap production Flexibility in molding structures Can mold large and intricate patterns, very low cost, Ultra large basic shape production Low cost and quick turn around Very strong, flexible, cheap parts. Several finishing and production options. Complex geometries are possible. Strong and flexible parts Stiff, more structural parts Useful for extremely critical dimensioned designs, no mold costs Excellent for scaled down concept models Great for making molds and rarely duplicates of parts our of specific metal materials Cons Weaker parts than other processes, Very high upfront costs Long process times, expensive raw material costs Weaker parts, limited geometry Only adept at making shallow parts, Processing can be difficult, limited geometry Poor product consistency, heavy flash issues VERY limited geometry Very small tolerances are difficult to form, slower than high- speed processes Slower processing and very difficult to form complex geometries Limited geomtry, additional machines req’d for various materials, parts aren’t as flexible Very high costs, slow process, size limitations Very expensive, fragile, cannot be easily modified, Size Restrictions Not useful for production and expensive Sterling Technologies | 10047 Keystone Drive • Lake City, PA 16423 | 814.774.2500 | SterlingRotationalMolding.comPDF Image | GUIDE TO PLASTIC ROTATIONAL MOLDING
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