Thermoset production and processing
Modern industry has a whole range of sophisticated methods for processing plastics.
As specialists in plastics in general and thermosets in particular, we are very familiar with the properties of various manufacturing and processing methods. How the plastics are processed depends on the purpose for which our customers order thermoset components.
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Casting or injection molding, pressing, embossing - these basic processes describe the processing of polymer materials in a nutshell. Let's take a brief look at each individual area: How exactly do the production and processing of thermoset work?
Similar to thermoplastics, injection molding is often used for thermosets. This enables thermoset components with high wall thicknesses of up to 50 millimetres. In general, there is a very high degree of design freedom, meaning that undercuts or more complex component elements can also be molded using slide technology. During injection molding, the thermoset raw material is prepared using the injection unit. For this purpose, the thermoset is fed into a cylinder tube with a screw conveyor. During the dosing process, the thermosets melt and become pasty. At temperatures of 105°C-115°C, the thermoset raw material is injected into the injection mold through a screw nozzle. In this injection mold, which is heated up to 190°C, the component is then formed and the thermoset is chemically cross-linked.
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A screw conveyor feeds the starting material into the injection mold at a pressure of up to 2,500 bar. Important for thermoset injection molding: The temperatures must be maintained. Depending on the material, the barrel must be brought to a temperature of between 20 and 110 °C for the dosing quantity. The injection mold needs the right temperature for curing, which also depends on the material - it is normally between 150 and 190°C.
Once the workpiece, the injection molded part, is fully cured by cross-linking, it can be ejected from the tool while still hot. In the case of complex geometries and high quality requirements, removal from the injection mold is often carried out by a robot to prevent damage and enable defined storage and further use.
The injection molding process has been further developed for the injection compression molding of thermosets. The process has advantages for the production of very large components, for example, and is also frequently used for thermoplastics. However, thermosets can also be processed using the embossing process. Another advantage of this process is that the shape of the fillers is influenced by the embossing process. If, for example, there is a requirement for the fillers to be present in all three spatial axes in as non-directional a manner as possible, the embossing process is very useful. The thermal expansion will also be much more uniform if the fillers are distributed in a non-directional manner. Furthermore, positive special effects can be achieved through partial embossing processes, which are necessary depending on the application and requirements.
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Injection molding, also known as transfer molding or transfer moulding, is a tried-and-tested process for producing moulded parts under pressure and heat.
Injection molding or transfer molding combines the advantages of injection molding with those of compression molding.
In this process, pre-products of the future component are heated and then injected into a transfer mold. For this purpose, pre-plasticized thermoset portions are often prepared in an extruder and then placed in a transfer mould.
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Compression molding is a common method in the production of composite materials today. The preheated plastic, often in tablet form in the case of free-flowing thermosets, is placed in an open mold.
In the press, the thermoset compound is cross-linked at precisely defined pressures and temperatures. This process ensures the desired cross-linking of the thermoset molecules at the chemical level.
Compression molding is also used in the processing of elastomers, which are also cross-linking plastics.
The mold is usually filled from above with the thermoset plastic in question and then evenly pressurized. In this way, the mold touches the material from all sides. Curing takes place under certain temperatures and suitable pressure. In this way, thermoset products with high mechanical strength can be manufactured. The geometry is usually less complex, as compression molding does not generally involve the use of complex injection moulding tools with slide technology.
At Baumgarten, we adapt to each order and each project individually: The processing of thermosets and therefore the production of your articles is directly tailored to the respective component. Your requirements are our starting point for finding a highly suitable solution for your application based on our decades of experience.
Depending on which properties are required for the finished product, different methods of thermoset processing are available.
With injection compression molding, we achieve high mechanical strength and a different, often absolutely necessary dimensional shape than with injection molding, for example.
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As long-standing specialists in the processing of a wide range of thermosets and the manufacture of complex thermoset precision components, we are familiar with the intricacies of the various processes - and select the most efficient approach for your specific order.
Let us advise you on our comprehensive range of thermoset services!
Do you have specific questions about the production and processing of thermosets, the possible Properties or about the plastics used? We are there for you with knowledge and active support.
Our services include thermoset-compatible design, the manufacture of prototypes and the production of large series. You too can benefit from our extensive experience.
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