Category Archive: Thermoset Molding
Using Inserts in Thermoset Molding
Injection molders and OEMs have been using various styles of inserts in their plastic parts and product applications to mechanically fasten separate components together for quite some time. Thermoset molded parts are no different. Depending on the application type, environment the application is used in, and geometries of the molded parts, there are many options to using inserts in a product design. Inserts can be molded-in during the molding cycle or tapped/press-fit into the part after molding. Where a part with complex geometries may have very high tooling costs or a high scrap/fallout rate during molding, inserts can be used to fasten and secure multiple parts together without molding the application into a single part. (more…)
Many potential customers are unsure whether a thermoplastic or thermoset molding material is best for their product application. The answer depends on the material property requirements of the product application. How the product is used, and the environment the product operates in are two of the biggest variables to determine if a thermoset or thermoplastic is best. Using a thermoplastic in an application that requires material performance properties of thermosets could cause product or material failure in the field, so it is important to understand how each material can affect your product and its cost to manufacture. (more…)
As engineers and product designers continue to try and maximize efficiency and minimize costs in existing or new product applications, thermoset composites are increasingly becoming a material conversion option for performance-sensitive, price-conscious applications that have traditionally been manufactured in metallic materials. Whether converting for cost, performance, or commercial reasons, thermoset composites are allowing engineers to “do more with less” within new and existing product applications. (more…)
Many of our customers or prospective customers ask about thermoset molding. What is it? Can you injection mold thermosets? How does it differ from thermoplastic injection molding (ie, nylon, ABS, PP)? How does it process? (more…)
As a custom thermoset molder, Woodland Plastics sees a vast variety of product applications and components we mold for our customers. Regardless of whether the application is a large or small part, a basic part design or components with complex geometries; thermoset molded parts will always require a deflashing method to eliminate excess flash around the part. It’s important for thermoset molders to mold parts with enough flash to produce a full part, but limit flash enough so there is no issues in removing the excess material flash or taking too much time to remove the flash. (more…)
Thermoset parts and components may be manufactured in similar molding processes as thermoplastics such as nylon, ABS, and polypropylene. The most popular molding processes for thermosets are injection, compression, injection-compression hybrid, transfer, and insert molding. Each molding process offers various benefits and disadvantages which molders and OEM’s must compare with their product requirements before building the tooling to mold parts. (more…)
With decades of thermoset molding experience including injection molding for phenolic resins, or phenolic molding compounds, a common question asked by our customers is if their application should be post-baked. The answer: “It depends”. While post-baking molded phenolics may provide increased property performance, it is not needed or recommended for all phenolic molding applications. (more…)
Thermosets are processed in similar functions to thermoplastics such as nylon, ABS, polypropylene, etc. Thermosets may be injection molded, compression molded, injection-compression molded, or transfer molded. Additionally thermosets can utilize molded-in inserts within the molding process. (more…)
What is a manufacturing ERP system?
Manufacturing ERP is a business management software system that streamlines manufacturing operations and data to provide a real-time view of its core business processes. While manufacturers can tailor their own ERP applications to relevant avenues of their manufacturing operations, some common applications included in a manufacturing ERP system may include real time production data tracking, production capacity and downtime, order processing and entry, inventory management, and quality documentation, and employee payroll, amongst others. (more…)
Because thermoset plastics may be injection molded, the tooling design for a thermoset injection molded part or component must include a runner and gate to allow the thermoset material to flow, or fill, from the molding machine barrel to the mold in order to produce the part. The type of gate used, and its location, can positively or negatively affect a final molded part in its cosmetic appearance and physical dimensions. Proper gate design allows material to flow evenly throughout the tool to produce the molded part, minimizing scrap from unpacked parts or short shots. (more…)
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