Bahagian Pembentuk Plastik Pembuat: Extrusion Moulding Vs Thermoforming

Pengilang bahagian yang dibentuk plastik menawarkan kepelbagaian mengenai teknik cetakan. Sebagai tambahan kepada kaedah cetakan yang popular seperti suntikan  dan putaran. Terdapat dua teknik cetakan yang lebih berkesan iaitu Thermoforming dan Extrusion Moulding.

Both of these techniques offer a number of benefits. They come with their advantages and disadvantages. Although, both techniques offer to end up moulding plastic, but the way they go about it is different. In this article, we are going to talk about the difference between these two techniques.

What a Plastic Molded Parts Manufacturer has to say about these techniques?

Having a basic understanding of both these techniques would help you make a better decision when it comes to choosing a plastic moulding method for your custom plastic parts.

Extrusion Molding

The process of extrusion molding is similar to that of injection molding. However, there is a slight difference, it tends to produce a long continuous shape. In addition, extrusion molding does not use a mold, on the contrary, it uses a die.

To make the parts, the technique squeezes hot raw material via a custom die. To make it easier for you to understand, we can say that it is like squeezing play Doh via a shaped hole. Unlike other molding techniques that put resins into a mould, extrusion puts it directly into the die shape.

So, here the die instead of the mold determines the shape of the desired product.

The Step by Step Process

Langkah 1: Raw plastic material including powder, pellets, granules are put into a hopper, later the material is shifted into an extruder. It is a hot long cylindrical chamber. To move the material through the chamber, it uses a revolving screw.

There are some extruders more than one revolving screw.

Step 2: There is a spinning screw operating, the raw material flows from the hoppers onto this spinning screw. For the operation of the spinning screw, it uses a horizontal barrel.

Step 3: Since every material has different properties, therefore the heating for every raw material is different. The temperature requirement of a certain material is taken into account. To form the desired shape, the molten plastic is passed through the die.

It is the small opening present at the end of the heated chamber.

Langkah 4: For the cooling purposes, the plastic extruded from the die is placed onto a conveyor belt. A plastic molded parts manufacturer can use either air or water for the cooling down purpose.

Prosesnya serupa dengan proses suntikan. Walau bagaimanapun, bukannya acuan, di sini anda akan menggunakan die.

Langkah 5:  Penting untuk merancang die untuk setiap profil plastik individu. Ini akan memastikan kelancaran aliran plastik dari profil silinder ke extruder. Oleh itu, mengambil bentuk akhir.

Untuk memastikan bahawa produk akhir menawarkan integriti, konsistensi dalam aliran sangat diperlukan.

Penggunaan Biasa Ekstrusi

Sekiranya anda mahukan bahagian-bahagian tersebut mempunyai profil penampang, gunakan teknik cetakan penyemperitan. Contohnya, paip PVC, selang, dan jerami. Tidak perlu bahagian menjadi bulat. Walau bagaimanapun, sangat penting bagi mereka untuk mempunyai bentuk yang sama sepanjang bahagiannya.

Apabila anda membandingkan kos pengacuan penyemperitan dengan proses pengacuan lain, anda akan menyedari bahawa ia menjimatkan kos. Terutama kerana die dan mesinnya sederhana. Mereka tidak mempunyai kerumitan yang semula jadi dalam acuan dan mesin proses pengacuan lain.

Oleh kerana ia tidak mempunyai kerumitan, maka ia mempunyai batasannya. Anda hanya boleh membuat sebilangan produk melalui teknik tertentu ini.

Kegunaan Pengacuan Ekstrusi Terbaik

Anda boleh merancang dan mengeluarkan bahagian yang ringkas dan mempunyai profil keratan rentas yang tetap. Contohnya, produk mempunyai bentuk bulatan dan segi empat sama.

Produk Biasa

• Talang plastik
• Paip PVC
• Dek plastik
• Jerami dan Selang

Pembentukan terma

Thermoforming is an effective manufacturing process in which the sheet plastic – thermoplastic—is heated to forming temperature. The reason for doing so is to allow the sheet to form the specific shape in the mould.

It later is trimmed to create products. The great thing about thermoplastic sheets is that it comes in a wide range of materials, thickness, finishes, and colors.

To achieve the final product thermoforming does not reply to a certain type of process or a mould. On the contrary, it uses multiple molds along with the different processes to acquire the required shape. For 3D products, it is generally a single 3D mould.

Plastic Mould Parts Manufacturer uses aluminum for the creation of these 3D molds. Since the technique uses less pressure, therefore, it is possible to create parts or components at a lower rate.

Types of Thermoforming

There are two basic types of thermoforming: pressure forming and vacuum forming. Both techniques yield effective results, but there is a slight difference between the two.

Vacuum forming uses pressure and heat to draw the plastic into the respective shape. It first heats the sheet and then places it into the mould. To ensure that the plastic takes the final shape, it is manipulated using the vacuum.

Pressure forming, on the other hand, is similar to a vacuum. However, it has the additional benefit of pressure. With pressure, it is possible to achieve greater details and texture. Therefore, if you have to choose, between the two, pressure forming is the better choice.

Thermoforming Common Uses

Thermoforming, especially the tin-gauge is extremely popular for producing trays blisters, containers, disposable cups, clamshells, lids among other things. It is common among the food as we ass the general retail industry.

For something more sturdy and bigger, manufacturers go with the thick-gauge thermoforming. For instance, it is an effective technique for refrigerator liners, vehicle doors, utility vehicle beds, and dash panels.

Cost and Time of Production

The thermoforming may be an inexpensive plastic moulding technique; however, it does take time. On average, you would need around 8 weeks for the thermoform mold to be ready. After the mold is ready, production starts.

The manufacturing phase is faster. However, do bear in mind that the cost of the technique greatly depends upon the size of the part of the component. For instance, if you want to mold small size parts, it would cost you $20,000 a year.

Whereas, the same amount of parts with a bigger size would cost you $50,000 a year.

You can also check out our article on how to reduce cost per unit.

Plastic Molded Parts Manufacturer Offering the following benefits

Here are the benefits of both Thermoforming as well as the Extrusion molding technique.

Extrusion Molding Advantages

High speed, High Volume

Proses ini menjimatkan kos apabila anda ingin mengeluarkan sebilangan besar komponen atau komponen. Ia juga dapat menghasilkan bahagian dengan cepat.

Kos rendah

Apabila anda membandingkan pengacuan penyemperitan dengan sebilangan teknik cetakan lain seperti Putaran, anda akan merasa berpatutan. Lebih-lebih lagi ia membolehkan kemudahan menggunakan semula bahan sisa, mengurangkan bukan sahaja hasil sampah tetapi juga kos.

Jenteranya kuat, boleh beroperasi secara berterusan. Pengilang dapat menikmati tempoh pembuatan 24 jam sehari.

Kelenturan

Produk dilengkapi dengan keratan rentas yang konsisten; namun, ia menawarkan fleksibiliti yang besar. Anda dapat menikmati sebilangan bentuk, ukuran, dan tekstur dengan proses pencetakan penyemperitan.

Manfaat Thermoforming

Kebolehsuaian

Thermoforming offers a number of benefits, design adaptability being on top. The technique offers the flexibility of incorporating all consumer design needs.

Fast Turn-Around Time

Of course, for full-on production, the mold does take some time. However, in the case of the prototype, it can deliver effective results within no time. It offers a fast turn around time.

Material Optimization

With Thermoforming it is possible to optimize materials in order to ensure lower tooling costs as well as cost-effective manufacturing.

Moreover, the technique offers a number of other benefits. It results in a very aesthetically pleasing component or part. The plastic molded parts manufacturer offers paintable plastics, colored plastics, along with several other customization options.