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Another notable advantage of polymer solution casting technology is that the total manufacturing cost for both prototyping and production volumes are frequently less than the conventional technologies. This cost benefit results from the use of inexpensive molds coupled with the scalability and adaptability of the manufacturing line.
A major polycarbonate market is the production of compact discs, DVDs, and Blu-ray discs. [13] These discs are produced by injection-molding polycarbonate into a mold cavity that has on one side a metal stamper containing a negative image of the disc data, while the other mold side is a mirrored surface.
For example, plastic manufacturer Sabic has a polypropylene food contact grade plastic which is specifically designed for thin wall margarine containers and lids. [7] Another plastic manufacturer, Bayer, makes a blend of Polycarbonate (PC) and Acrylonitrile butadiene styrene (ABS) specifically designed to make thin wall mobile housings. [8]
The power required for this process of injection moulding depends on many things and varies between materials used. Manufacturing Processes Reference Guide states that the power requirements depend on "a material's specific gravity, melting point, thermal conductivity, part size, and molding rate." Below is a table from page 243 of the same ...
[5] This process is the same as a regular extrusion process up until the die. There are three main types of dies used in this process: annular (or crosshead), spider, and spiral. Annular dies are the simplest, and rely on the polymer melt channeling around the entire cross section of the die before exiting the die; this can result in uneven flow.
A process flow diagram (PFD) is a diagram commonly used in chemical and process engineering to indicate the general flow of plant processes and equipment. The PFD displays the relationship between major equipment of a plant facility and does not show minor details such as piping details and designations.
Extrusion line for plastic laces. Die forming typically occurs immediately after polymer melt has exited an extruder. The most basic process involves guiding the stream of molten polymer under pressure through a die, which three distinct regions: manifold, approach, and lip.
Injection mold construction is the process of creating molds that are used to perform injection molding operations using an injection molding machine. These are generally used to produce plastic parts using a core and a cavity. Molds are designed as two-plate or three-plate molds, depending on the type of component to be manufactured.