TRANSFER MOULDING

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PLANNING

INTRODUCTION
For some applications, it is desirable to close the mold first and
then introduce the molding compound in its fluid state through a
small opening or gate leading to the mold cavity or cavities. This
technique is called transfer or plunger molding.
This is variation of compression molding and is particularly valuable
when intricate shapes have to be molded.
It is also useful when metal inserts have to be incorporated (as in
electrical component).

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PROCESS
OPERATIONS:
In transfer moulding, a known amount of moulding powder is placed
in a heated chamber (transfer pot), outside of the mould. When
liquefaction is completed a piston forces the resin through a
connecting channel into the mould.
As in compression moulding the mould is kept heated and this
completes the chemical reaction which leads to hardening of the
moulding. A systematic diagram of Transfer Moulding is shown in
fig.1.
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Fig. 1

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TRUE TRANSFER OR POT TYPE TRANSFER MOULDING

In true transfer or pot type transfer moulding, the mould is closed
and then placed in an open press. The charge of moulding compound
is introduced into an open pot at the top of the mould. The plunger is
then placed into the pot and the press is closed. As the press closes,
it pushes against the plunger, which in turn exerts pressure on the
moulding compound, forcing it down through a vertical passage
called a sprue and through runners and gates into the cavities. After
the curing, the mould is removed from the press, the plunger is
withdrawn, the mould is opened, and the parts are ejected. (Fig. 2)
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Fig. 2

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Plunger Transfer Mold

MOULDING SEQUENCE
The mould is closed and material is placed into the hot transfer
chamber of fully automatic transfer moulding and plastication.

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Fig. 3

MOULDING SEQUENCE
The plunger descends into the pot, causing material to melt and
flow through runners into hot mould cavities.

Fig. 4
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Curing under the pressure of transfer ram.

MOULDING SEQUENCE
After cure, the press opens, the plunger retracts, and parts are ejected
with cull and runners.

Fig. 5

Deflashing and mould cleaning

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ADVANTAGES
Tool maintenance is generally low, although gates and runners are
susceptible to normal wear.
Because the mold is closed before the process begins, delicate
inserts and sections can be molded.
Higher tensile strengths are easier to obtain with transfer molding.
Automatic de-gating of the mold's tunnel gates provides cosmetic
advantages.

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LIMITATIONS
The cull and runner system of transfer molding leaves waste
material, but this scrap can be greatly reduced by injection
molding with live sprues
Fiber degradation of orientation occurring in the gate and
runner system reduces the molded part's impact strength.
Compared to compression molding, high molding pressures are
required for the transfer process

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USEFUL DATA
Recommended temperature range for thermosetting moulding compounds
Material
Temp C
TempF
Phenol-formaldehyde

140-160
290-350
Melamine- formaldehyde

135-160
280-350
Urea- formaldehyde

135-160
275-310
Polyester

80-150
180-300
Diallyl phthalate

120-165
250-325
Epoxy

140-200
290-390
Silicone

150-190
300-370
Recommended moulding pressures for compression moulding thermosets
Type of Filler
Mouding Pressure (PSI)
Type of Filler
Mouding Pressure (PSI)
PHENOLIC
Woodflour
1500 3500
Mica
1500 3000
Cotton flock
1500 4500
Asbestos
2000 4000
Macerated cotton
2000 5000
Mineral
2000 3000
Tire cord
2000 5000
Glass:
Diced Squares
2000 10000
Choppes roving
2000 6000
Bulk
1000 - 6000
Sisal
2000 5000
Rubber
1500 3000
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USEFUL DATA
Type of Filler

Mouding Pressure (PSI)

UREA
Alpha cellulose
Alpha cellulose plus plasticizer
MELAMINE
Alpha cellulose
Asbestos
Mineral
Glass :
Chopped roving
Bulk

4000 8000
2000 4000
2000 8000
2000 8000
2000 6000

Type of Filler
Mouding Pressure (PSI)
DIALLYL PHTHALATE (DAP)
Synthetic (Nylon, orlon, dacron)
500 2000
Glass Fibre
500 2000
Asbestos
500 2000
POLYESTER
Glass fibre (premix)
50 500
Sisal
50 500
Mineral (clay)
50 300

2000 8000
2000 - 6000
EPOXY

ALKYDS
Mineral (granular)
Glass :
Extruded rope
Putty
Bulk

1000 - 1500

Mineral
Glass fibre

600 1000
400 800
1000 2500

Asbestos
Glass fibre
Mineral

100 1000
100 2000
SILICONE

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1000 8000
1000 5000
1000 5000

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