Introduction to Extrusion Molding
Extrusion is
one of the most widely used manufacturing processes across many industries.
Essentially, it is not much different from squeezing tooth paste out of the
tube. Anything that is long with a consistent cross section is probably made by
extrusion. Common examples are spaghetti, candy canes, chewing gums, drinking
straws, plumbing pipes, door insulation seals, optical fibers, and steel or
aluminum I-beams.
The plastic
extrusion molding process usually begins with a thermoplastic in the form of
pellets or granules. They are usually stored in a hopper (a funnel-shaped
receptacle) before they are delivered to a heated barrel. The molten plastic is
then forced through a shaped orifice, usually a custom steel die with shape of
the cross section of the intended part, forming a tube-like or rod-like
continuous workpiece. Cooling of the workpiece should be as even as possible.
Extrusion
molding maintains a constant cross-section to keep the cost down in almost all
cases. Most thermoplastics can be used for extrusion. However, materials with
higher stiffness and/or strength in the molten state are usually preferred
since they are easier to form and maintain the desired shape. Other
considerations regarding material selection may include heat and UV stability
(for longevity), flame and chemical resistance (for safety), and strength and
flexibility (for utility).
Pros and Cons of Extrusion Molding
👍Pros
- Low initial setup costs
- Fast setup time
- Low production costs
👎Cons
- Moderate production speed
- Mediocre precision
- Limited to parts with a uniform cross section
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