Plastics Processing and Safety Issues

1. Plastics Processingand Safety Issues

2. Foam Processing

3. Foam Processing Nerf balls, invented by Reynolds Guyer and developed by Parker Brothers, are made from synthetic foam. Polyurethane material has CO₂ released into it during processing, creating the air pockets within the ball that make it lightweight, soft and pliable.

4. Foam Processing To create the spongy foam material, NERF begins with a reaction between polyester and a diisocyanate.

5. Foam Processing The air pockets in the foam come from the release of carbon dioxide during another reaction.

6. Silicone Molds & Plastic Resins

7. Mold Casting • Open mold • Closed Mold

8. Mold Casting • Low pressure • You can use flexible molds • It is easy to get undercuts and intricate details that are more difficult in some of the other process

9. Silicone Molds & Plastic Resins http://www.b9robotresource.com/molding1.htm

10. Vacuum Thermoforming • The process involves heating a plastic sheet made of a thermoplastic until soft. • The softened sheet is draped over a mold. • A vacuum sucks the sheet into/onto the mold. • The newly shaped sheet is taken off the mold.

11. Vacuum Thermoforming Sheet of plastic  Heated (soft)  Molded using a shaped die

12. Vacuum Thermoforming

13. Vacuum Thermoforming Advantages: • Vacuum forming uses low pressures so only relatively low cost equipment/components are required. • Low pressures mean that moulds can be made of inexpensive materials and in a short time.. 

14. Vacuum Thermoforming Disadvantages: • More complicated machines and moulds are needed for automatic or continuous production of ‘high volume’ items, eg. disposable cups and sandwich packs. • The vacuum forming process starts with a flat plastic sheet and there may be a need for a second process to trim the moulded end product. This means more expense to obtain additional equipment.

15. Fiber Glass Graphite Fiber Lay up processes These processes use composite materials – plastics made up of polymers and added material such as fiber glass or graphite fiber

16. Uses of Composites Composite Bicycle Laminated Fiberglass Bow Graphite Snowboard

17. Uses of Composites Dodge Viper Front grill of an Automobile Different parts of an airplane

18. Hand Lay-up Resins are impregnated by hand into fibres which are in the form of woven, knitted, stitched or bonded fabrics. Laminates are left to cure under standard atmospheric conditions.

19. Laminated Composites Laminated composites can be thought of as sheets of continuous fiber composites laminated such that each layer has the fiber oriented in a given direction.

22. Wet lay up

23. Spray lay up

24. Other Types of Processes • Injection molding • Blow molding • Injection blow molding • Extrusion • Rotational molding • And many others!

25. Injection Molding - Probably the most common, most important, most economical process

26. Injection Molding

27. Blow Molding • Air pressure is used to inflate soft plastic into a mold cavity • Material limited to: thermoplastics • Accomplished in two steps: • Fabrication of a starting tube, called a: parison • Inflation of the tube to desired final shape • Two methods: • Extrusion blow molding • Injection blow molding

28. Preform is injection molded Preform is placed in the blow molding machine Preform is heated Preform is pressurized Part is removed Injection Blow Molding PET Preform

29. Injection Blow Molding

30. Preforms Placed in Mold

31. Formed Bottles

32. Safety Issues • Mechanical and pressure dangers • Thermal dangers • Eye protection (plastics are brittle) • Proper tools • Workable safety rules • Compliance with legal rules and guidelines • Gloves • Loose clothing • Emergency procedures • Proper training • Cleanliness

33. Safety First

34. Preventable Accidents

35. Preventable Accidents

36. Preventable Accidents