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Thermoset Injection Vs Compression Moulding

Choosing the better: Thermoset injection or thermoset compression

Selecting an appropriate molding process for your production requires insights into the designs and the application the final product intends to serve. Business owners must have a clear understanding of the benefits of a molding technique and its impact on end-users before sourcing the build tools. Factors like design geometrics, material property requirement, and the usage of moulded inserts also affect the choice of the best molding methods. Those struggling with their perfect choice can go through this article, which covers the benefits and suitability of both thermoset injection molding and thermoset compression molding in detail.

Thermoset Injection molding process

The injection molding method is a very common molding technique adopted across industries in India. The best advantage of a Thermoset injection molding method is the faster cycle time that facilitates faster and higher throughput in a shift- probably why several top industries like home industries and automotive part making industries highly rely upon the thermoset injection molding method for large scale productions. Injection molding manufacturing is the most reliable plastic manufacturing methods that produce and ship the products quickly and in large volumes. Read through the advantages of injection moulding process, explained by the one of the best plastic moulding companies in India.

Advantages of an injection molding process

Saves time: Injection molding methods save almost 50 per cent of production time than other molding techniques. This is possible by enabling the molding of thermoset products in multiple cavity moulds every day.

Reduced production cost: Apart from aiding faster and high volume production, the thermoset injection molding uses less time in a single shift, reducing the per-unit cost significantly.

Increased throughput: A high volume production in a single run is a quality inherent to injection molding techniques. Saved up ptoduction time also allows other jobs to run in the meanwhile.

Design flexibility: Hailed as the best molding processes by product designers and engineers, the technology also offers design flexibility. As the thermoset injection moulders have a gate that leads to spruce and runner, design hacks like moving parting lines, allowing even dispersion of materials and improving the flow of materials can be introduced. Also, enabling the feeding of  materials like mineral fibres and glasses, designers can now create geometrical patterns and unique and aesthetic shapes.

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However, despite the umpteen advantages the technique exhibits, the injection moldings are not the appropriate choice for a few applications. One such instance is forming a weld line or knit line in the places where materials fuse. Certain component designs should not have knit lines and are therefore recommended compression molding for production. Since the processes do not have a gate or screw-barrel combination, compressed moulded products are free from weld lines.

If you like to know more about the compression molding technique, continue reading.

Thermoset Compression molding technique

In a thermoset injection molding method, the materials are fed through the hoppers that are again gradually led to the injection unit consisting of a barrel and screw. The problem arises when the materials comprising glass fibre fillers are fed into the gate. When the glass fibres move through the preheated barrel through the screw, they could get chopped and dispersed unevenly throughout the unit. Dispersing of materials can result in the reduced strength of the product. Here is where the benefits of a compression molding process strike a note.

In a compression molding method, the glass materials are not chopped or dispersed as in the injection molding method. The glass fillers are strategically fed wherever the strength is required. This is the reason why the technique is applied in the manufacturing of products that requires high strength. However, a few disadvantages like the ones listed below make the compression-molding technique a less sought-after technique.

  • One of the biggest disadvantages of the compression molding technique is its inability to produce high-volume outputs due to the lower molding cycle time.
  • While injection molding is an automatic process most of the time, compression molding requires a robot or an operator to load the materials and take out the finished product.

While these are a few common pointers that need to be checked before finalizing the manufacturing process, the final decision must be taken only after reviewing the future requirement and the end-use of the product.