Author Archives: Woodland Plastics

  1. BMC Molding

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    BMC, or Bulk Molding Compound, is a type of thermoset composite molding material. BMCs are unsaturated polyesters or vinyl esters, and can be injection or compression molded with thermoset molding machines. The properties of BMC molded parts include exceptional dielectric strength, electrical insulation, heat resistance, and chemical resistance. These end properties lend BMC to be molded for a variety of safety-critical components in Electrical, Automotive, and Industrial markets. In its raw state, BMC resembles a play-dough like form usually filled with glass fibers and or minerals dispersed within the resin system. Molding wise, BMCs are generally injection molded, but can also be compression molded. Injection molding BMCs require the use of a molding machine stuffer or ram to help injection material into the screw and barrel. (more…)

  2. Why Thermoset Parts Need to be Deflashed

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    “Deflashing” is a secondary manufacturing process in thermoset molding to remove excess material or “flash” from molded parts. Whereas a thermoplastic molded part is molded as a finished part ready to ship, thermoset molded parts must be flashed with excess material around the part to avoid molding defects and short shots. The parts can be deflashed manually by hand using a file or ceramic knife, or it can be in a more automated, batch process by tumbling the parts in deflash equipment that blasts media at the part to remove the flash. Media used to deflash the parts in deflash equipment includes thermoplastic media, walnut shells, or other abrasive materials that is strong enough to remove the part without damaging any part details or dimensions. (more…)

  3. Thermosets Plastics for Electrical Components

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    Why are thermosets commonly used in injection molding applications for electrical parts and components? Thermosets exude exceptional electrical stability, high dielectric strength, and resistance to arc and track to protect electrical products and internal components from electrical charge. Parts including circuit breakers, terminal blocks, and electrical connectors are molded from thermoset materials to ensure product safety. Whereas a thermoplastic can degrade, disfigure, or ignite; thermosets such as unsaturated polyester BMC and phenolic molding compounds remain durable and strong when exposed to such electrical elements. (more…)

  4. Thermoset vs Thermoplastic Injection Molding

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    Thermoset and thermoplastic materials are two types of plastic molding materials. Each type of material can be injection molded, however the injection molding process differs between each type of resin. While injection molded parts from both thermoset and thermoplastic may have similar aesthetics, the two material types can exude drastically different material performance properties. Thermosets are a material of choice for rugged, industrial type applications requiring high heat resistance or exceptional electrical properties to avoid damage from electrical current. Choosing the correct molding material type depends on the end use application and what material property requirements the end-product needs to withstand to function properly and ensure safety. While thermoplastic materials are more commonly used, product applications requiring further material performance in the areas of electrical strength, heat resistance, and chemical resistance are likely to rely on thermosets as the molding material of choice. (more…)

  5. What Plastics are Thermoset?

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    Thermosets are a niche grade of plastic or composite molding materials compared to common engineered thermoplastics such as PA66 (nylons), ABS, Polypropylene, etc. While thermosets are much less known, they have been used in various components longer than thermoplastics. The original plastic material, bakelite, created by Leo Baekeland in 1907 was a type of thermoset composite. Although thermoset materials have been molded and used in components dating back a century ago, thermosets are now used commonly towards specialty end use applications that experience high heat or electrical current. Where a thermoplastic molded part may degrade and disfigure under such elements, thermosets remain durable and strong due to the high temperature resistance and dielectric strength. (more…)

  6. Thermoset Molding for High Temperature Components

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    Thermosets are used in molding applications requiring an end-part or product assembly to remain dimensionally stable within challenging and aggressive environments. Resistance to high temperatures and heat is one of the major benefits of designing a component with a molded thermoset vs a thermoplastic material. Molded thermoset parts exhibit very good dimensional stability in high heat and high operating temperatures. Thermoset materials provide components with properties of heat resistance up to 400F-500F continuous operating temperatures depending on the material formulation, whereas thermoplastic molding materials such as a nylon or ABS may disfigure, melt, or carbonize and jeopardize the integrity of a product or assembly when exposed to similar temperatures. If a part or product assembly must withstand high operating temperatures and aggressive end-use elements, choosing a thermoset as your molding material may help keep your product assembly remain safe and functioning as intended. (more…)

  7. Deflashing Thermoset Parts

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    While thermoplastic and thermoset molded parts may appear similar, one difference between molded parts is that thermoset parts are molded with excess material or “flash”, and must be deflashed after they are molded, whereas thermoplastics are molded without excess flash. Flash is excess molding material needed in thermoset molding to fully form a part and avoid bad or rejected parts. In order to mold a full part, thermosets must be molded with excess material flash, otherwise the part integrity may be jeopardized by shorts, burns or other molding defects. Regardless of whether a molded thermoset part is molded into basic or complex geometries, it will always require a secondary deflash operation. Removing the excess flash can be done in a variety of ways, depending on what is most suitable to the part and volume requirements. (more…)

  8. Molded Thermosets for Kitchen Appliance Products

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    Thermosets are used in products in a variety of industries. Electrical and automotive are two heavy users of molded thermoset components due to thermoset materials durability and protection against high temperatures and electrical current. Another industry that relies on the unique properties of thermoset molding materials is the home and consumer appliance market. Whether a product is a larger home appliance, or countertop cookware appliance, molded thermosets are used for elements and components touching high operating temperatures or requiring protection against electrical elements. (more…)

  9. Converting Parts from Metal to Thermoset

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    Engineers and product designers convert the design of existing parts and components from metals or to thermoset plastics in applications for a variety of material property advantages and benefits to the application. While metal components may require costly secondary machining operations to manufacture a part, thermosets may be molded into complex geometries and shapes. Incorporating thermoset materials into a product design may allow for consolidation of multiple parts of an assembly, as well as reduce overall weight of a product or assembly compared with metallic parts. For high-volume applications, thermosets offer a highly scalable solution to meet increasing product demand and volume requirements with low waste. (more…)

  10. Thermoset Molding Processes

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    As a moldable plastic composite, thermosets can be molded in similar molding processes as thermoplastics such as nylon, ABS, and polypropylene. They can be injection molded, compression molded, and transfer molded. Each molding process offers different benefits and disadvantages depending on the finished part’s geometry, assembly, and commercial aspects of the program. OEMs and molders must take into consideration all variables of a part and how it is used to determine the best molding process to make the part. While there may be multiple molding processes that can successfully produce the part, some processes may be more advantageous based on pricing or quality specifications. (more…)

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