1.

2.0

Objective
1.1

To develop practical skills in compression molding technique for polymer

materials.

1.2

To investigate the effect of cure time and cure temperature to the compressed
polymer product.

Introduction
Compression molding is designed to facilitate the replacement of metal compound with

polymer and other composite. A compression molding machine is a kind of press which is
oriented vertically with two molding halves (top and bottom halves). The method used in
compression molding is polymer is being preheated and placed into an open, heated mould
cavity. After the preheating process, the mould will close with a top plug and pressure is applied
to force the material to contact all areas of the mould. The process (heat and pressure) is
maintained until the polymer cured whether in room temperature or at the elevated temperature.

Figure 1 : Compression Molding Process

This molding process can be employed with thermosets, thermoplastics and advanced
composite thermoplastics but thermosets are the most used material in this molding process.
Compression molding is a high volume and pressure molding method, which is suitable for
producing complex and high strength products.Compression molding process has high
production rate since the mold cycle time is short, other than that it can produce a good
flexibility in parts design and the raw material wastage also minimum.

3.0

Component and Equipment

Figure 2 : Compression Molding Components

4.0

Procedure

Temperature, time and pressure required was set for curing or hardening of sample
for the two platens hot press

Rectangular mould was pre-heat by placing it on the lower platens of hot press until the
hot press temperature achieved.

Heated mould was removed fromlower platens and plastics resin was placed in the
mould cavity.

Line the mould plate with plastics sheet for both side to get smooth surface of final
product.

Press start button of the machine to move up lower platens until the mould nearly touch
the upper platens.Sample was pre-heat for 5 minutes, then the press is closed
completely for an additional 8 minutes

Return button was pressed to allow lower platens return to its original position when
compression process was completed.

When cure was completed, the cured sample was immidiately taken out and cooled at
room temperature using water or cooling machine.

Cured sample was trimmed and cutted into required shape.

Procedure was repeated using different cure time and cure temperature.

5.0

Result and Discussion

Table 1 : TPS : PLA

TPS : PLA [20:80]

Melting Temperature
Pre-Heat Time
Test Time
Cooling Time

180C
6 min
6 min
3 min

Table 2 : HDPE

HDPE
Melting Temperature
Pre-Heat Time
Test Time
Cooling Time

180C
3 min
4 min
5 min

In this lab, we are using HDPE and TPS:PLA sample to be test with compression
molding machine. TPS:PLA sample had same melting temperature with HDPE which is 180C
but it have a slight difference in pre-heat time, pressure time and the cooling time. This might be
caused by the difference in properties for each sample. TPS:PLA have longer pre-heat time than
HDPE which is 3 minutes more than HDPE, the test time for TPS:PLA also longer than HDPE
by more than 2 minute than HDPE. It is different with cooling time, the cooling time required for
HDPE is longer than TPS:PLA.

7.0

Lab Question
1. Define the method of compression molding.
The basis of this molding is the female mold and a male mold plunger or can be known as
platen and for the male it is usually using hydraulic system which come together with a
pre-heated, carefully measured quantity of sample between them and partially cured.
Pressure is applied after those processes and the pressure applied might reach hundred
tons. Cooling need to be included in the process before the mold is opened so that the
component is not ejected. After the cooling process, the mold can be open to see the
product produced from the sample used. Excessive material or known as flash may be
found after the mold is open, the flash need to be removed.

2. Determine four primary factors in a successful compression molding process.

a) Amount of materials.
b) Heating time and technique.
c) Force applied to the mold.
d) Cooling time and technique.

3. What are the pros and cons of compression molding.

PROS

CONS

Good surface finish with different texture and Due to expensive machinery and parts, the
styling can be achieved.
initial capital investment associated with
compression molding is high.
Raw material wastage is minimum.
Maintenance cost is low.

Uneven parting lines

There is limitation on mold depth

Extra features like inserts, bosses and Sometimes secondary processing (trimming,
attachment can be molded in during the machining) of product is required after
processing.
compression molding.

The process is suitable for high production

High part uniformity is achieved with volume. It is not economical for making
compression molding process.
small number of parts or for prototyping
applications.

Production rate is high as the mold cycle time

is in few minutes.

Twisting and shrinkage in product is reduced

therefore dimensional accuracy

Good flexibility in part design is possible.

8.0

Reference
1. Sperling, L.H. (2001). Introduction to Physical Polymer Science. New York: WileyInterscience.
2. Strong, A.B. (2000). Plastics: Materials and Processing. 2nd. ed. New Jersey: PrenticeHall.
3. http://www.plasticmoulding.ca/techniques/compression moulding.htm
4. http://dtresource.com/compression-moulding.html
5. http://www.plasticmoulding.ca/techniques/compression_moulding.htm
6. http://www.upcinc.com/resources/materials/HDPE.html