Pexco Leverages Engineering Advancements in Product Design

September 6, 2024  |  , ,

Plastics have revolutionized tool and process design across various industries, offering a multitude of advantages that enhance functionality, efficiency, and cost-effectiveness. Here’s how plastics contribute to these advancements:

  • Design Flexibility and Customization: Performance plastics can be molded into intricate shapes and sizes, providing unparalleled design flexibility. This ability allows for the creation of highly specialized parts tailored to specific applications. Unlike metals, which require extensive machining, plastics can be precisely shaped during manufacturing processes like injection molding, making it easier to achieve complex geometries and detailed features.
  • Cost Efficiency: The use of performance plastics such as FEP/PFA often results in significant cost savings. Plastics are generally less expensive than metals, and their manufacturing processes, such as injection molding and extrusion, are cost-effective, especially for high-volume production. The lower material and processing costs contribute to a reduction in the overall expenses associated with tool production.
  • Performance Enhancements: Plastics offer a range of performance benefits that enhance part functionality. Performance plastics are resistant to wear and environmental corrosion, which helps in extending the lifespan of tools and minimizing maintenance needs. Additionally, plastics can be engineered to have low friction properties, reducing wear and tear on moving parts and improving the efficiency of mechanical components.
  • Precision and Consistency: Plastics can be manufactured with high precision and consistency, ensuring that tools perform reliably and meet stringent specifications. This precision is crucial for applications requiring exact measurements and high performance. The uniformity in plastic components helps maintain consistent quality and reliability in tools.
  • Innovation in Process Design: Plastics enable innovative process designs by allowing for the integration of multiple functions into a single component. This capability reduces the need for assembly and can streamline manufacturing processes. Moreover, the lightweight nature of plastics can lead to ergonomic improvements, making tools easier to handle and reducing user fatigue.
  • Thermal and Electrical Properties: Certain plastics are designed to provide excellent thermal and electrical insulation, making them suitable for tools and components that need to operate safely in challenging environments. Advanced plastics can also withstand high temperatures, expanding their applicability in processes involving heat.

Performance plastics enhance tool and process design through their flexibility, cost efficiency, performance improvements, and innovative potential. As material science evolves, the role of plastics in advancing tool design and manufacturing processes continues to expand, driving both practical and sustainable advancements in various industries.

Pexco engineers are experts in metal-to-plastic conversions. Performance Plastics uses various grades of resins as metal replacements in applications where historically only metal was an option. Performance plastics are widely used in industries such as aerospace, medical, industrial, and energy (fossil fuel and renewable). To discover how resins can make the transition from metal to thermoplastic easier, please visit our website at https://pexco.com or contact our office at (513) 321-8404

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Pexco provides expertise in fluoropolymer solutions for a range of industries including Aerospace, Medical, Energy, & Semiconductor

August 15, 2024  |  , ,

Fluoropolymers are versatile materials that have revolutionized several key industries through their unique properties. These high-performance polymers, known for their resistance to heat, chemicals, and electrical conductivity, offer tailored solutions across the aerospace, medical, energy, semiconductor, and military sectors.

 

 

Aerospace

In the aerospace industry, fluoropolymers are crucial due to their exceptional thermal stability and resistance to harsh environmental conditions. Materials such as FEP and PFA are used in insulating wires and cables, ensuring reliable performance in extreme temperatures and pressures of space. Additionally, fluoropolymers’ low friction properties make them ideal for lubricants and coatings in aerospace components, reducing wear and tear and extending the lifespan of critical parts.

Medical

The medical field benefits immensely from fluoropolymers, particularly in applications requiring biocompatibility and sterilization. Polymers including PEEK are used in a variety of medical devices, including catheter coatings and surgical instruments, due to their ability to withstand repeated sterilization processes and their resistance to bodily fluids. Their non-reactive nature ensures that medical devices remain safe and effective, minimizing the risk of adverse reactions.

Energy

In the energy sector, fluoropolymers play a significant role in improving efficiency and safety. The chemical resistance of fluoropolymers like Torlon® makes them ideal for lining pipes and tanks used in handling aggressive substances, including acids and hydrocarbons. Additionally, fluoropolymer coatings are used to protect equipment from corrosion and wear, extending the service life of components and reducing maintenance costs. In renewable energy, these polymers enhance the performance and durability of solar panels and wind turbines by providing excellent weather resistance.

Semiconductor

The semiconductor industry relies on fluoropolymers for their role in manufacturing cleanroom environments and in the fabrication of electronic components. Their low outgassing properties and chemical inertness are crucial in preventing contamination in sensitive semiconductor processes. Fluoropolymers like injection molded PFA are used in everything from coatings on wafer carriers to insulators in electronic devices, ensuring precision and reliability in the production of high-tech components.

Military

In the military sector, fluoropolymers offer exceptional performance in demanding conditions. They are used in protective coatings for equipment and gear, providing resistance to chemicals, extreme temperatures, and abrasion. Fluoropolymers such as Ultem PEI also contribute to the development of advanced materials with specialized properties, such as stealth technology and advanced armor, enhancing the effectiveness and durability of military assets.

In conclusion, fluoropolymers are indispensable across various high-tech and demanding industries. Their unique properties—such as chemical resistance, thermal stability, and low friction—make them ideal for applications where performance and reliability are critical. As technology continues to advance, the role of fluoropolymers in these industries is likely to expand, driving innovation and ensuring that the needs of these sectors are met with cutting-edge materials.

Pexco specializes in fluoropolymers and has a staff of experts to assist you in material selection.  For more information on how Pexco can assist you with your next project, please visit our website at www.pexco.com,  or contact our office at 513.321.8404.

 

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Pexco’s Packaging & Assembly Services

August 8, 2024  |  ,

 

At Pexco, we understand the crucial role that packaging and assembly play in the success of your business. That’s why we offer comprehensive Packaging & Assembly Services designed to help streamline your manufacturing process, from initial concept to final delivery.

Our state-of-the-art facilities and skilled workforce are ready to handle all your packaging and assembly needs, ensuring your products are market-ready, on time, and within budget.

 

 

Our services include:

  • Custom Packaging
  • Custom Assembly
  • Custom Machining
  • Special & Private Label Packaging
  • Clean Room Services
  • Painting
  • Kitting

Custom Packaging

We specialize in custom solutions that meet your specific needs, moving away from the one-size-fits-all approach.

Custom Assembly

Our service can integrate multiple components into an individual package to reduce handling time and streamlineyour supply chain.

Custom Machining

Pexco possesses extensive knowledge in plastic design and component machinability for your final products. Services include:

  • Plastic Machining Lathe
  • Plastic Milling
  • Polishing (vapor & mechanical)
  • Annealing

Comprehensive Packaging Expertise

Pexco offers extensive expertise in delivering a wide range of diverse packaging and assembly solutions across B2B and B2C markets. We help simplify the process of moving from concept to a final packaged product.

Clean Room Services

We provide specialized packaging environments for industries such as medical devices, pharmaceuticals,semiconductors, electronics, and more.

Plastic Painting Services

Pexco offers specialized painting services, making painting an economical option for your product.  Whether decorative or functional, we offer a wide range of paint selections, textures and finishes.

Kitting

Our custom kit solutions enable your business to maintain its agility amidst changing production demands.  Our kit assembly services enhance resource efficiency by optimizing performance and seamlessly integrating into your operations.

Pexco specializes in many value-added services designed to streamline your business.  For more information on how Pexco can assist you with your next project, please visit our website at www.pexco.com,  or contact our office at 513.321.8404.

 

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Pexco Specializes in High-Performance Fluoropolymer Molding & Extrusion Technologies

August 1, 2024  |  , ,

Fluoropolymers are used in many industries, including aerospace, pharmaceutical, medical, and semi-conductors where they are used for seals, gaskets, bushings, bearings, hoses, tubing, wiring, even fiber optics cladding and semi-conductors. There are multiple ways to manufacture parts and components made from fluoropolymers, injection molding and profile extrusion are two of the most efficient.

What Are Fluoropolymers?

Fluoropolymers,as the name no doubt implies, are polymers that are based on bonding between fluorine and carbon. The first fluoropolymer was PTFE (polytetrafluoroethylene), which is perhaps better known by its trade name Teflon. Other common fluoropolymers include ETFE (ethylene tetrafluoroethylene), PFA (perfluoroalkoxy alkane), PVDF (polyvinylidene fluoride), PVF(perfluoralkoxy), FEP (fluorinated ethylene propylene), and ECTFE (ethylenechlorotrifluoroethylene).

Fluoropolymers are popular materials because of their properties which include resistance to high temperatures, chemical attacks, and electrical current. They are also low friction, non-toxic, exhibit minimal aging and leaching of chemicals. In addition, many fluoropolymers are biocompatible, making them ideal for medical applications.

  • Injection Molding: This process involves melting the fluoropolymer resin pellets andinjecting the molten material into a mold cavity under high pressure. Oncecooled and solidified, the part is ejected from the mold. Injection molding issuitable for producing intricate shapes with high precision and is commonlyused for smaller, complex parts.
  • Profile Extrusion: In this method, the fluoropolymer resin is melted and forced through a die that shapes it into a continuous profile of the desired cross-section. The profile is then cooled and cut to the desired lengths.Profile extrusion is often used for manufacturing longer, continuous shapes such as tubing, rods, and strips.

Both processes have their advantages depending on the specific requirements of the part, such as size, complexity, and production volume.

Working with fluoropolymers can be challenging, but not impossible.  Selection of the right polymer material for the application and consideration of processing parameters like tooling designare crucial for successful manufacturing. Materials like PFA and FEP are known for their melt-processability, making them suitable for the molding process.

Pexco’s specialization in high-performance fluoropolymer molding and extrusion technologies makes us a valuable partner for industries requiring components made from fluoropolymers. Our expertise in utilizing processes like injection molding and profile extrusion helps us meet specific requirements for parts interms of size, complexity, and production volume.

For more information on how Pexco can assist you with your next extrusion project, please visit our website at www.pexco.com, or contact our office at 513.321.8404.

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Pexco Offers Advanced Extrusion & Compression Techniques

July 25, 2024  |  , ,

Pexco utilizes advanced extrusion techniques encompassing arange of sophisticated manufacturing methods to produce profiles, tubes, and multi-layered products with specific properties and configurations. Here’s an overview of each technique:

 

 

Profile Extrusion

  • Definition: Profile extrusion involves extruding plastics such as ABS, TBE, PE, and PC into a continuous shape that can vary in complexity, from simple designs to intricate profiles with specific cross-sections.
  • Advanced Techniques:
    • Precision Control: Utilizing advanced die designand computer-controlled extrusion systems to achieve precise dimensionsand surface finishes.
    • Co-extrusion: Integrating multiple materials or layers during the extrusion process to impart desired properties such as color, texture, or functional attributes.
    • In-line Processing: Incorporating secondary operations such as cutting, punching, or coating directly into the extrusion line for enhanced productivity and versatility.
  • Applications: Profiles are used extensively in construction (window frames, decking), automotive (trim and seals), and consumer goods (furniture components, appliance trims).

Tube Extrusion:

  • Definition: Tube extrusion involves the extrusion of plastics such as HDPE, FEP/PFA, and ETFE to create hollow tubes of various diameters and wall thicknesses.
  • Advanced Techniques:
    • Micro extrusion: Producing very small diameter tubes with high precision, often used in medical devices (catheters, tubing for drug delivery).
    • Multi-layer Extrusion: Extruding tubes with multiple layers to achieve specific properties like barrier resistance or flexibility.
    • High-speed Extrusion: Implementing advanced cooling and handling systems to maintain dimensional stability and surface quality at high extrusion speeds.
  • Applications: Tubes find application in industries such as healthcare (medical tubing), industrial (piping and conduits), and food processing (packaging and conveying).

Co-Extrusion:

  • Definition: Co-extrusion involves extruding multiple layers of different materials such as PTFE, ABS and PE,  simultaneously to form a single continuous profile or tube.
  • Advanced Techniques:
    • Barrier Properties: Creating structures with enhanced barrier properties against gases, moisture, or UV radiation.
    • Functional Integration: Combining materials with different properties (e.g., stiffness, flexibility) within a single extruded product.
    • Multi-color Extrusion: Producing profiles or tubes with distinct color layers without secondary painting or coating processes.
    • Applications: Widely used in packaging (food packaging films, bottles), construction (multi-layer pipes), and automotive (multi-material trim components).

 

Tri-Extrusion and Crosshead Extrusion:

  • Tri-Extrusion:
    • Definition: Tri-extrusion involves the simultaneous extrusion of three different materials such as ABS, PC , and PP  layers to create complex profiles or tubes.
    • Applications: Enables the production of products requiring three distinct layers with specific performance characteristics, such as  weatherability, strength, and aesthetic appeal.
  • Crosshead Extrusion:
    • Definition: Crosshead extrusion is a technique used in cable and wire manufacturing to apply an additional layer of insulation or jacketing around a core conductor.
    • Advanced Techniques: Precise control over thethickness and uniformity of the extruded layer, ensuring electricalinsulation properties and mechanical protection.
    • Applications: Essential in the production of cables for telecommunications, automotive wiring harnesses, and industrial powercables.

Benefits and Applications:

  • Benefits: Advanced extrusion techniques offer benefits such as increased production efficiency, precise control over material properties, customization of products with multiple layers or profiles, and integration of functional features. Typical materials include PVC, HDPE, LDPE, and nylon.
  • Applications: These techniques are essential in various industries including automotive,  medical, packaging, and electronics, where they enable the creation of lightweight, durable, and high-performance components tailored to specific requirements.

 

Pexco specializes in advanced extrusion techniques such as profile extrusion, tube extrusion, co-extrusion, tri-extrusion, and crosshead extrusion.  These techniques play pivotal roles in modern manufacturing, facilitating the production of complex, multi-functional plastic products across a wide range of applications and industries.  We leverage years of expertise to bring your product to market – on time and on budget.

 

For more information on how Pexco can assist you with your next extrusion project, please visit our website at www.pexco.com,or contact our office at 513.321.8404.

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Solving Your Most Difficult Challenges – Custom Plastic Manufacturing Capabilities

July 18, 2024  |  , ,

At Pexco, our strength lies in our solution diversity.  From custom solutions to solving specific engineering challenges, our expertise guarantees outstanding results. Pexco has been helping our customers bring ideas to life for nearly half a century.

Pexco specializes in the manufacturing of extruded, injection, and compression molded plastic parts. We deliver customized manufacturing solutions to meet the specific needs of each customer.  These solutions can help companies of all sizes accelerate time-to-revenue, lower production costs, and establish a flexible, resilient, and scalable supply chain for custom manufacturing. Each of these methods has its strengths depending on the complexity, volume, and specific requirements of the item.  Below is a brief outline of each method, and their typical advantages:

Extrusion Molding:

Extrusion Molding is used to form plastic materials into a pre-defined shape. During the process, the material is melted and pushed through an extrusion molding machine, forming a long, tube-like shape or rod.  This is cooled and cut to the required specs.

  • Process: Plastic material is melted and pushed through a die to create a continuous profile.
  • Advantages: Suitable for producing continuous shapes with consistent cross-sections. It’s efficient for high-volume production of items like pipes, tubes, and some profiles.
  • Materials:  Silicone, Polysulfone, Polycarbonate & Acrylic

Injection Molding:

Injection molding is a manufacturing technology for the mass production of identical plastic parts with good to tight tolerances.  The materials are first melted and then injected under pressure into a mold, where the liquid plastic cools and solidifies.

  • Process: Molten plastic is injected into a mold cavity under high pressure and cooled to form the part.
  • Advantages: Ideal for complex shapes and precise dimensions. It’s highly automated and efficient for large production runs, offering good repeatability and minimal material waste.
  • Materials:  Peek, Ultem PEI & Torlon® PAI

Compression Molding:

Compression molding is a forming process in which a plastic material is placed directly into a heated metal mold then is softened by the heat and therefore forced to conform to the shape ofthe mold.

  • Process: Plastic material is placed in a heated mold cavity, then compressed to shape the part
  • Advantages: Suitable for large parts and materials that require high-strength properties. It can be more cost effective for smaller production runs compared to injection molding.
  • Materials: PTFE

Pexco specializes in manufacturing extruded, injection, and compression molded plastic parts. We leverage years of expertise to bring your product to market – on time and on budget.

For more information on Pexco and how we can help you with your project, please visit our website at www.pexco.com.

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Let Pexco Solve Your Most Difficult Challenges

July 11, 2024  |  , , ,

Pexco.locations

At Pexco, our strength lies in our solution diversity.  From custom solutions to solving specific engineering challenges, our expertise guarantees outstanding results. From inspiration to application, Pexco has been helping our customers bring ideas to life for nearly half a century.

Pexco embrases the value of working together as One Pexco. This philosphy drives business-level product innovation, location efficiencies, client responsiveness and helps us attract talent. We are able to take advantage of the economies of scale, scope and skill while creating strong accountability and ownership, by pushing decision making down as close to the customer as possible.

Pexco places great value on firm-wide coordination in decision-making, cooperative teamwork and institutional committment. We have one way of doing things and utilize cross-facility teams to address client innovation.

Pexco’s multiple specialty manufacturing facilities across North America help control costs and provide the flexibility needed for fast and efficient product delivery.  And with 13 locations nationwide, we can meet most of your market’s product needs, On-time and on budget:

  • Asheboro, NC   
  • Athol, CT
  • Atlanta, GA – Headquarters
  • Bristol, CT
  • Cincinnati, OH
  • Grand Falls, NB, CA
  • Monterey, MX
  • Philadelphia, PA
  • Plastow, NH
  • Ravena, OH
  • Sparta, NJ
  • Tacoma, WA
  • Wallingford, CT

Pexco specializes in manufacturing extruded, injection, and compression molded plastic parts.  We leverage years of expertise to bring your product to market – on-time and on-budget.

For more information on One Pexco and how we can help you with your project, please contact Rich Reed, Vice President of Sales – Custom, at [email protected] or visit our website at www.pexco.com.

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Molding Techniques – How to Choose the Best Process for your Project

June 27, 2024  |  , , ,

Plastic Molding Comparison

In manufacturing, molding refers to the process of shaping material into a rigid form. Pexco is the North American Leader in plastic molding, offering our customers a variety of techniques and materials to best meet their needs.

Choosing the appropriate molding process for manufacturing plastic parts depends on several factors, including the design, size, complexity, production volume, and material properties required. Here’s an overview of when to use each type of molding:

Plastic Injection Molding

Plastic Injection Molding is a process that involves heating a polymer above its melting point and then injecting the molten resin into a mold.

  • High-Volume Production: Ideal for producing large quantities of identical parts.
  • Complex Geometries: Suitable for intricate designs with detailed features and tight tolerances.
  • Material Variety: Can be used with a wide range of thermoplastic and thermosetting polymers, such as FEP, PFA, PAI (Torlon®), Peek, and PEI (Ultem®).

Blow Molding

Blow molding is the forming of a hollow object by inflating or blowing a molten polymer into the outside shape of the mold.

  • Hollow Parts: Best for making hollow objects, such as bottles and containers.
  • Medium to High Production Volumes: Economical for large production runs in materials such as HDPE, PP, PETG and PC.
  • Lightweight Products: Ideal for products where weight reduction is important.

Compression Molding

Compression Molding is a process that uses heat, pressure, and time to shape pre-measured materials into parts with various lengths, thicknesses, and complexities.

  • Large, Flat, or Curved Parts: Suitable for producing large and relatively simple parts.
  • Thermosetting Materials: Commonly used for thermosetting plastics and composites such as silicone, polyurethane and phenolic.
  • Low to Medium Production Volumes: Effective for lower production volumes than injection molding.

Extrusion Molding

Extrusion molding is used to form plastic materials into pre-defined shapes.

  • Suited for long, hollow formed applications.
  • Continuous Profiles: Best for creating long continuous shapes with a consistent cross-section in materials such as acrylic, polycarbonate, PVC and polyethylene.
  • High Production Volumes: Economical for high-volume production of parts.

Rotational Molding

Rotational molding is a technique that creates hollow plastic parts of any size. A hollow mold is filled with powdered resin, and the mold rotates bi-axially and then is transferred to an over.  The mold continues to rotate as the resin melts and coats the wall of the mold.

  • Relatively low-cost tooling.
  • High durability, stability, and strength using materials such as LDPE, HDPE, PP and PO (nylon).
  • Fine-detail surface textures, symbols and/or lettering

Thermoforming

Thermoforming is the process a heating a thermoplastic sheet or block to its softening point.  The items are then stretched across a single-sided mold and manipulated into the desired shape.

  • Flexibility and low cost of entry
  • Durability, color and texture options using materials such as ABS, HDPE, PVC, and PC.
  • Sustainability

Choosing the right molding process depends on the project’s specific requirements, including its design, material, production volume, and cost considerations. Each method offers distinct advantages that make it suitable for different applications.

Pexco offers expertise in material engineering, materials and processing and can assist you in choosing the best process for your project.  Pexco processes over 500 different materials including FEP, PFA, PAI, PEEL, PPS, PEI, acrylic, polycarbonate, PVC and polyethylene, and can help you find the best fit for your next project.

For more information on these processes, materials, or how Pexco can help you with your project, please contact Rich Reed, Vice President of Sales – Custom, at [email protected] or visit our website at www.performanceplastics.com.

 

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Thermoplastics, Elastomers and Thermosets

June 20, 2024  |  , , ,

 

What material is best for my project?

 

Thermoplastics, elastomers, and thermosets are three distinct classes of polymers, each with unique properties and characteristics.  How do you know which one is best for your project?

Thermoplastics:

  • Definition: Thermoplastics are polymers that become pliable or moldable when heated and solidify upon cooling. This process can be repeated multiple times without significant degradation.
  • Behavior: They soften when heated and can be reshaped or remolded, making them highly versatilefor manufacturing processes like injection molding, extrusion, and 3D printing.
  • Properties:
    • They typically have good impact resistance and mechanical strength, depending on the specific type.
    • Examples include polyethylene (PE), polypropylene (PP), polystyrene (PS), and polyvinyl chloride (PVC).
    • They are recyclable and often used in a wide range of applications from packaging and consumer goods to automotive parts and medical devices.

Elastomers:

  • Definition: Elastomers are polymers that exhibit elastic properties, meaning they can return to their original shape after deformation when the applied stress is removed.
  • Behavior: They are characterized by their ability to stretch significantly and then retract to their initial shape, due to the cross-linked polymer chains.
  • Properties:
    • They have excellent elasticity, resilience, and fatigue resistance.
    • Examples include natural rubber, silicone rubber, and polyurethane elastomers.
    • Elastomers find applications in seals, gaskets, tires, footwear, and various vibration dampening components.

Thermosets:

  • Definition: Thermosets are polymers that undergo a chemical reaction (often called curing or cross-linking) during processing, leading to a permanently set shape.
  • Behavior: Once cured,thermosets cannot be remolded or reshaped by heating, as they undergo a chemical change that irreversibly hardens them.
  • Properties:
    • They typically have excellent dimensional stability, high temperature resistance, and chemical resistance.
    • Examples include epoxy resins, phenolic resins, and polyurethane thermosets.
    • Thermosets are commonly used in applications requiring durable and heat-resistant materials such as in electronics, aerospace, automotive parts, and in household appliances.

Key Differences:

Response to Heat:

  • Thermoplastics: Soften with heat and can be reshaped.
  • Elastomers: Can stretch and return to their original shape due to elasticity.
  • Thermosets: Hardenirreversibly with heat or chemical curing.

Recyclability:

  • Thermoplastics: Generally recyclable.
  • Elastomers: Recycling potential varies; some can be recycled.
  • Thermosets: Difficult to recycle due to their irreversible curing process.

Applications:

  • Thermoplastics: Widely used in consumer goods, packaging, and automotive industries.
  • Elastomers: Commonly found in seals, tires, and flexible components.
  • Thermosets: Used in applications requiring heat resistance and durability, such as electronics and aerospace.

Understanding these differences helps inselecting the appropriate polymer for specific engineering, manufacturing, orproduct design needs based on properties like flexibility, durability, and recyclability.

Performance Plastics, a Pexco Company, has experts in material engineering that can assist you in choosing the best material class for your project.

Fort more information on any of these materials, or how Pexco can help you with your custom project, please contact Rich Reed, Vice President of Sales – Custom, at [email protected] or visit our website at www.performanceplastics.com

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Get to know the differences between Plastic Injection Molding and Plastic Extrusion

May 24, 2024  |  , ,

Plastic injection molding and plastic extrusion are both popular manufacturing processes used to create plastic parts, but they differ significantly in their methods and applications. While they both produce high quality flurorpolymer parts, plastic injection molding produces three-dimensional shapes vs. plastic extrusion produces linear, two-dimensional shapes.

 

 

 

Process:

  • Injection Molding:  This process involves injecting molten plastic material into a mold cavity, where it cools and solidifies to form the desired shape. The mold typically consists of two halves and the material is injected under high pressure.
  • Extrusion:  In extrusion, plastic material is melted and forced through a die tocreate a continuous profile. The die gives the plastic its desired shape,and the material is cooled and solidified as it exits the die.

Equipment:

  •  Injection Molding:  Injection molding machines consist of a hopper where the plastic pelletsare fed into a heated barrel. Inside the barrel, the pellets melt and are injected into the mold cavity.
  •  Extrusion:  Extrusion machinery includes an extruder, which is essentially a long barrel with a screw conveyor inside. The plastic pellets are fed into one end of the extruder, where they are heated, melted, and forced through a die at the other end.

Applications:

  • Injection Molding:  This process is commonly used for producing intricate and complex parts with high precision and repeatability. It’s used in industries such as aerospace/defense, industrial, electronics, and medical devices.
  • Extrusion:  Extrusion is often used to create continuous lengths of plastic profiles or sheets with a consistent cross-section. It’s employed in applications such as pipes, tubing, window frames, and traffic control items.

Complexity and Cost:

  •  Injection Molding:  Tooling costs for injection molding can be higher due to the need for precision molds, especially for complex parts. However, once the mold is made, the cost per part can be relatively low.
  • Extrusion:  Extrusion tooling costs are generally lower compared to injection molding, especially for simple profiles. However, the process may not be as suitable for highly complex shapes.

Material Variation:

  • Injection Molding:  A wide range of thermoplastics such as FEP, PFA, Torlon, etc., can be used in injection molding, allowing for flexibility in material selection.
  • Extrusion:  While extrusion also supports various fluoropolymer materials, the process is particularly suited for thermoplastics that can be melted and reshaped repeatedly.

In summary, while both plastic injection molding and plastic extrusion are versatile manufacturing processes used in the plastics industry, they each have applications suited to different types of products and applications.

Plastic injection molding is best applied to three-dimensional shapes, while plastic extrusion is best suited for two-dimensional shapes.

For more information on the best molding application for your project, please contact Rich Reed, Vice President – Custom, at [email protected] or visit our website at www.performanceplastics.com.

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