Compression molding is a manufacturing process that creates a number of different products. It is popular as it is useful in producing both rubber and plastic products However, it can also be used for sealants. Used in a variety of applications, the process is part of products you use in your everyday life. This includes automotive parts, household products, electrical insulation, sealants, and gaskets. You may wonder, what is compression molding? Below you will find more information about the manufacturing process.
What Is Compression Molding?
Compression and transfer molding is a process where material is placed in a heated mold. Once in the mold, pressure is applied to shape the material. The process is highly effective as it uses both heat and pressure. This creates strong and durable materials. The step-by-step process of compression molding is outlined below.
Preparation
The first step in the process is material preparation. The material is a prepared solid and is usually made from rubber or plastic. It is essentially performed to look similar to the final product. Once the material is prepared, the mold is preheated. It is made of two parts to make the material much easier to shape.
Material Placement and Curing
The preformed material is placed inside the mold after it has been preheated. Once inside, the separate parts of the mold are placed together and pressure is applied. The pressure then forces the material into the desired shape. The combined heat and pressure cure the material. Curing involves the hardening and solidification of the material. Depending on the size and type of the material, this can take a few minutes to a few hours.
Final Product
Once the material has been fully cured, it takes the shape of the mold. The mold is then removed and excess material is trimmed off. From there, the material can be used in the desired application.
Common Materials Used in Compression Molding
Compression molds often use thermoset materials. This type of material is characterized by the fact that they cannot be melted down once they have been set. This means that heating them up and curing them creates a final product. There are several different sealing solutions and materials. If you are considering what materials to use for your applications, the following are the most common materials.
Rubber
Both natural and synthetic rubbers are widely used in compression molding. This type of material is used in products that need to be durable and flexible. It is also beneficial as rubber is resistant to wear and tear.
Plastics
Plastic is a common material used in compression molding. Some of the plastic materials include epoxy, phenolic, and melanin. These thermoset materials are strong and heat-resistant which is why they are used often.
Is Compression Molding Right for Your Application?
Compression molding offers several advantages over alternative methods. Consider the following if you are on the fence about what to choose.
Reduced Material Waste
Compression molding conserves material waste which can save you a lot of time and money in the long run. It only uses what is necessary and can fit within the mold. Any extra material after the curing process has finished is removed and recycled. However, this is a marginal amount as compared to other methods.
Cost-Effective
Compression molding is a cost-effective solution if you are molding large parts. While there is an initial investment into the mold, the overall cost per part is much lower. This can offer long-term benefits to your business’s bottom line.
Customization
Compression molding offers maximum customization. The mold can be in different shapes and sizes to meet your application’s needs. This is helpful for so many industries as precision is critical in compression molding.
