Compression Molding

Jonathan Chodosh, Sherif Madkour,

Jesse McGrath
Compression Molding: What?
Is a processing technique that
combines forming the product along
with simultaneous curing of the resin.
High Pressure
Higher Temperature
Curing Agent
Development
1909 when Leo Hendrik Baekeland
phenol-formaldehyde resins
Patents on a automatic compression
machine date back to 1930
Development of C.M was hindered by
reaction knowledge.



Thermosets
Heat compression causes an irreversible
chemical charge in the plastic which
solidifies the part .
The plastic wont soften, so the mold
doesnt need to be cooled.
After short interval, the press is opened
and the molded part is removed.
Any plastic remaining in the mold is
removed by compressed air. The
operator breaks the flash.

Thermoplastic
Preheated in a dielectric heater.
The mold is cooled to a point where
the plastic retains enough integrity to
be removed from the mold without
partial distortion.
The same steps used for thermosets
are repeated here as well.
Advantages
Molds are
inexpensive
Labor costs vary
Great for large parts
Minimum waste
Dimensional
accuracy
Warping and
shrinkage minimized
Fast cycle(1-5
minutes)

High volume output
High quality surfaces
Complex parts
Disadvantages
No delicate pieces
Uneven parting
lines
High initial
investment
secondary
operations (e.g.
trimming)
Mold depth is
limited
Product
consistency

Considerations
Mold heating
Temperature, heating rate and heating
method
Compression rate
Max compression force
Curing time
How long until part can be removed from
mold.
Mold cooling rate
Mold cycling rate

Equations
T
*
= (T-T
0
)/(T
0
-T
ad
) = Reduced
Temperature
t
*
= (xt)/(h)
2
=Reduced Time

y*
= y/h = distance form slab centerline
T
0
=Original Temperature
T
ad
=Adiabatic Temperature
X=Thermal Diffusivity
h=Heat Transfer Coefficient between.
Mold and polymer
h= half thickness of slab.
Range of Materials
Thermoset Thermoplastic
Bulk molding
compound (BMC)
Sheet molding
compound (SMC)
Unidirectional tapes
Woven Fabrics
Chopped Strands
Randomly oriented
fabrics
Preforms

Pellets
Sheets
Extruded

Elastomers
Extruded
Typical Products
Automotive parts
Hoods, bumpers, fenders, spoilers, etc.
Medical equipment
Caps and plugs to blood separation
machines and ultrasound equipment
Aerospace
Electrical connectors to guided missiles


http://www.tqc.co.uk/images/bumper7.jp
g
http://www.rdmoulds.com/rdmoulds/ma/24%20fr
ont%20bumper%20molds.jpg
http://www.compositesworld.com/uploadedimages/Publications/CW/Artic
les/Internal/hoodHyundai.jpg
Transfer Molding
Hybrid between Injection and
Compression molding
Cross linking reaction is started prior
to placement in the mold
Resin is heated and put under pressure
Slushy mix is then forced into the
Mold.

This point on Transfer molding follows
the Compression molding process.
Benefits/Constraints of T.M.
Advantages Disadvantages
Rapid production rates
Largest Benefit over C.M.
Geometrical Accuracy
Intricate Parts Possible

Expensive molds
Expensive equipment
Much material loss
Size limitations of
products
References

http://composite.about.com/library/glossary/c/bldef-c1203.htm
http://twistertechnology.com/Process%20Capabilities.html
http://www.me.gatech.edu/jonathan.colton/me4793/compmold
.pdf
http://www.daprorubber.com/index.aspx
http://www.rdmoulds.com/rdmoulds/ma/24%20front%20bump
er%20molds.jpg
http://www.tqc.co.uk/images/bumper7.jpg
http://www.compositesworld.com/uploadedimages/Publication
s/CW/Articles/Internal/hoodHyundai.jpg
http://www.bsu.edu/web/jebutcher/compressionmolding.htm