Compression Molding |Process Explained | Polymer Matrix Composites |ENGINEERING STUDY MATERIALS

Compression Molding |Process Explained | Polymer Matrix Composites |ENGINEERING STUDY MATERIALS
Compression Moulding is a method of moulding in which the moulding material, generally preheated, is first placed in an open, heated mould cavity. The mould is closed with a top force or plug member, pressure is applied to force the material into contact with all mould areas, while heat and pressure are maintained until the moulding material has cured. The process employs thermosetting resins in a partially cured stage, either in the form of granules, putty-like masses, or preforms.

Compression molding is a high-volume, high-pressure method suitable for molding complex, high-strength fiberglass reinforcements. Advanced composite thermoplastics can also be compression molded with unidirectional tapes, woven fabrics, randomly oriented fiber mat or chopped strand. The advantage of compression molding is its ability to mold large, fairly intricate parts. Also, it is one of the lowest cost molding methods compared with other methods such as transfer molding and injection molding; moreover it wastes relatively little material, giving it an advantage when working with expensive compounds.

However, compression molding often provides poor product consistency and difficulty in controlling flashing, and it is not suitable for some types of parts. Fewer knit lines are produced and a smaller amount of fiber-length degradation is noticeable when compared to injection molding. Compression-molding is also suitable for ultra-large basic shape production in sizes beyond the capacity of extrusion techniques. Materials that are typically manufactured through compression molding include: Polyester fiberglass resin systems (SMC/BMC), Torlon, Vespel, Poly(p-phenylene sulfide) (PPS), and many grades of PEEK.

Compression molding is commonly utilized by product development engineers seeking cost effective rubber and silicone parts. Manufacturers of low volume compression molded components include PrintForm, 3D, STYS, and Aero MFG.

Compression molding was first developed to manufacture composite parts for metal replacement applications, compression molding is typically used to make larger flat or moderately curved parts. This method of molding is greatly used in manufacturing automotive parts such as hoods, fenders, scoops, spoilers, as well as smaller more intricate parts. The material to be molded is positioned in the mold cavity and the heated platens are closed by a hydraulic ram. Bulk molding compound (BMC) or sheet molding compound (SMC), are conformed to the mold form by the applied pressure and heated until the curing reaction occurs. SMC feed material usually is cut to conform to the surface area of the mold. The mold is then cooled and the part removed.

Mold and material behavior vary based on material types. New I-PRESS Servo Hydraulic technology provides end users with a greater degree of flexibility with press movement & pressure profiles and control of external devices such as automation to platen zone temperature control. With the latest of electronic servo motor to high pressure hydraulic pump users save considerable energy and the greatest in speed, distance, pressure, dwell time and burping movements.

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