The Advantages of Compression Molding as a Manufacturing Process
If there is one manufacturing process that has withstood time, it is compression molding. This process was developed in the 1850s as the original method for molding rubber. Up until now, it is still the method being used to manufacture rubber products of low to medium quantities and to produce bulky parts.
The compression molding process is simple. It is a traditional technique that involves the use of rubber compounds and creating a pre-form in the shape of the end product, which is larger than the final shape. A bit confusing? It is not. The process involves two factors: heat and pressure.
The resin material or rubber is formed using a heated mold and applied with the clamping pressure of the press to force the material inside the tool. A permanent chemical change called vulcanization occurs in the rubber, giving its shape. When vulcanization is complete, the product will be extracted from the mold, allowing it to cool. It will shrink during cooling until it reaches the final size.
The most common application of compression molding is machinery parts, wellington boots, door stops, and gaskets. It has high repeatability, therefore manufacturers can produce the same product several times.
Here are some advantages and disadvantages related to compression molding as a manufacturing process. It can help you decide whether this process is right for your product.
Advantages of Compression Molding Over Other Processes
-
Lower tooling cost
Since the process does not use transfer or injection, there is less tooling cost compared to what you will need for other molding processes. There are also no additional features on the design other than the cavity needed to produce the molded parts. The mold is usually made from aluminum or low-cost steel and saves on tooling. It only requires a tool that can withstand a tremendous amount of pressure.
-
Excellent for low volume production runs
Compression molding has a lower cost of investment on the mold tool. It is also cheaper to set up the press and start the process. That means, it is a cost-effective method for making smaller production of parts. The breakeven point can be easily reached because of the lower cost of tooling. It makes it viable for small production runs. In choosing the manufacturing method, the cost/benefit factor is an important consideration.
-
Excellent for producing large parts
This manufacturing process is excellent for producing large products that need a significant amount of material to manufacture. Since the material is directly loaded into the mold cavity, there is no restriction on the weight of the part that you can make. The only consideration would be the tonnage and press required.
-
No runners, gates, and sprues
Lastly, this manufacturing technique does not use runners, gates, or sprues. These are tooling features where the materials are passed through in other production methods. It consumes extra materials that translate to additional costs. On top of it all, it also disrupts the overall aesthetic needed for the product.
Conclusion
The compression molding process is an ideal production technique for manufacturing large parts. It has many advantages, including keeping the production cost to a minimum although individual part cost can be higher when compared with other techniques.
Search
Recent Posts
Categories
Archives
- Mar 2024
- Feb 2024
- Jan 2024
- Dec 2023
- Nov 2023
- Oct 2023
- Sep 2023
- Aug 2023
- Jul 2023
- Jun 2023
- May 2023
- Apr 2023
- Mar 2023
- Feb 2023
- Jan 2023
- Dec 2022
- Nov 2022
- Oct 2022
- Sep 2022
- Aug 2022
- Jul 2022
- Jun 2022
- May 2022
- Apr 2022
- Mar 2022
- Feb 2022
- Jan 2022
- Dec 2021
- Nov 2021
- Oct 2021
- Sep 2021
- Aug 2021
- Jul 2021
- Jun 2021
- May 2021
- Apr 2021
- Mar 2021
- Feb 2021
- Jan 2021
- Dec 2020
- Nov 2020
- Oct 2020
- Sep 2020
- Aug 2020
- Jul 2020
- Jun 2020
- May 2020
- Apr 2020
- Mar 2020
- Feb 2020
- Jan 2020
- Dec 2019
- Oct 2019
- Sep 2019
- Aug 2019
- Jul 2019
- Jun 2019
- May 2019