The Advantages & Disadvantages of Extrusion Molding
Manufacturing companies employ extrusion
molding to make products with a consistent cross-section. Common items found in
a home made by this process include PVC pipe, rain gutters and even straws. The
process works by pressing melted plastic through a die - a tool that provides
the correct shape. While the extrusion molding process offers advantages to
manufacturers, it has disadvantages as well.
Disadvantage – Size Variances
When the hot plastic exits the extruder, it
frequently expands. The expansion of the plastic at this stage of the process
is called die swell. Predicting the exact degree of expansion remains
problematic as it arises from different factors in the process. Due to
unpredictable expansion, manufacturers must often accept significant levels of
deviation from the product dimensions or tolerance. While methods exist to
limit this issue, the tolerance problem largely disqualifies extrusion molding
as a method for precision parts manufacturing.
Disadvantage – Product Limitations
The nature of the extrusion molding process
places limits on the kinds of products it can manufacture. For example, plastic
soda bottles narrow at one end to accommodate a cap, which normal extrusion
molding cannot achieve. Alternatives, such as extrusion blow molding do provide
an option for these types of products, but require investment in a different
type of extrusion equipment.
Advantage – Post-Extrusion Alterations
The plastic remains hot when it leaves the
extruder, which allows for post-extrusion manipulation. Manufacturers take
advantage of this and use a variety of rollers, dies and shoes to alter the
shape of the extruded plastic to fit their needs.
Advantage – Low Cost
Extrusion molding has a low cost relative
to other molding processes.This stems, in part, from the efficiency of the
process. Most extrusion molding uses thermoplastics, which can repeatedly
undergo melting and hardening. Leftover materials, normally discarded as waste
in other processes, can be reused. This lowers raw material and disposal costs.
Barring mechanical failure or planned downtime, plastic extrusion machines
operate continuously. This reduces the chances of inventory shortage and allows
for 24 hours-a-day manufacturing.
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