What are the advantages and disadvantages of compression mould?

Using a compression mould to process thermosetting polymers is one of the most effective methods for manufacturing composite molded products. It has a number of advantages. However, there are a few disadvantages. These include the cost and time of the process, and the fact that it is not suitable for large-scale mass production. In addition, the parts manufactured through this method are not recyclable, and the material used to make them may contain small specks of dirt.

Although these factors can limit its use in large-scale mass production, it is an efficient and economical method of producing components for the automobile industry. In addition, compression molding is ideal for making thin wall parts. It also has the advantage of being able to use a limited range of materials. Moreover, the cost of the parts produced after the mass production phase is very low.

In order to reduce the risk of surface defects, the material used in the compression moulding process must be a synthetic resin with good wetting and curing properties. These characteristics enable a good bond to form at the interface between the part and the mold. The resin can be made from vinyl, phenolic, or polyimide. It should also be selected based on its performance index.

Thermosets are the most common type of material used in compression molding. They offer strength to weight ratios that mimic metal properties. They are often used to manufacture components such as vehicle body panels and instrument panel supports. Several different types of thermosets are available. Some of the most common are polyurethane, epoxy, melamine, and alkyd resins.

The process is carried out by heating the raw materials in the mould, then applying pressure and cooling them. The heating temperature and compression pressure are determined based on the base polymer. The heating circuit is typically set at 190 degC. The heating and cooling rates can be as high as 8.5 K/s. It is important to keep the mould closed for a substantial portion of the cycle. Some systems combine low-pressure and high-pressure pumps to move the platens.

During the forming process, the temperature of the mould should be higher than the temperature of the polymer. This can improve the properties of the part and reduce by-products, which are created during the processing. This technique is also ideal for parts with tight tolerances. Traditionally, hydraulic systems have been used to run compression presses.

The moulds used for compression molding are usually simple, single-plane molds. They can be made from lower-cost steel or aluminium. In order to maximize productivity, some degree of automation is required. CAD software is commonly used to produce multiple iterations of the part.