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Compression
Molding

COMPRESSION MOLDING

• Is a processing
technique that
combines forming the
product along with
simultaneous curing of
the resin by applying
pressure and usually
heat.
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1) Charging a precise amount of molding compound,

into the bottom half of a heated mold;

2) Closing the mold halves together to compress the

charge, forcing it to flow and conform to the shape of the
cavity;

3) Heating the compound by means of the hot mold and

let it flow completely fulfill the mold;

4) Cooling to stabilize the products

5) Opening the mold halves and removing the part from

the cavity.
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Compression Molding Machine

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• A thermoset material can be ejected from the mold

after the proper curing cycle without the need to
cool the mold.
• A thermoplastics material need to cool the mold to
make the compound hardened, so that it can be
removed without distortion when the mould is
opened.
• Mold temperatures are usually in the range of
130-200C.
• Cycle times may be long (possibly several
minutes) so it is desirable to use multi-cavity
molds to increase production rates.
• A typical mold cycle is as follows: load material,
close press, mold open after cure period, remove
molded part, clean mold.
• Curing times range from 0.5 to 5 mins
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Preheating of Molding Compound

• In practice, the molding compound (powder or
dough) is usually preheated before it is put into
the mold.
• Preheating is usually done using:
a) infrared (IR) heaters
b) high frequency (HF) dielectric heating (such as
microwave ovens)
c) radio frequency (RF) heating
d) convection heating in a hot air oven
• Preheating converts the molding compound into a
uniformly softened material that flows cleanly and
evenly when the mold closes. 6

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 It also facilitates early flow in the mold, shortens the

molding cycle and reduces the temperature difference
between the feed and the mold.
 The practical advantages of preheating include:
a) better surface finish,
b) minimize flow marks
c) more uniform cure and shorter cure cycles
d) reduces the pressure required for compression
molding
e) improved electrical properties
f) articles with thick sections can be molded with less
difficulty.

In compression molding, the workpiece (pre-

shaped part, volume of powder, mixture of liquid
resin and fillers) is placed in the heated mold
and is formed under pressure.

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Stages in Compression molding

cycle

Parameters
1.The quantity of charge(molding material) put into the
mold

2.Pressure of the molding process

• Range of pressure 2000-3000 psi(13.8-20.7 MPa)

3.Mold temperature
• Temperature range 300ºF to 375ºF (149⁰C- 191⁰C)

4.Cure time variables.

• The period required to harden thermosetting material to
partial and complete polymerization is called cure time.

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3 types of Compression Mold (Mold

Closure)
a) Flash type
b) Positive type
c) Semi-positive (horizontal-flash and
vertical-flash)

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• Mold closure types

– Flash
Upper
Mold

Horizontal
Flash

Part

Lower
Mold

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• Mold closure types

– Semipositive

Upper
Mold

Part

Lower
Mold
Horizontal Land Separated Flash

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• Mold closure types

– Positive

Upper
Mold

Part

Lower
Mold
Small Gap
(no flash)

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• Compression molded parts

– Total force needed per part is determined
by:
• Projected area of the part (A)
• Required cavity pressure for the resin (PA)
• Pressure factor that accounts for depth (ρ)
• Depth in excess of the minimum amount (de)

F = (A) [(PA) + (ρde)]

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• Compression molding machines

– Total force that can be exerted is called:
• Press capacity
• Machine rating
• Machine size
• Rated in Newtons or Tons
– Determined by the area of the hydraulic
ram and the hydraulic pressure in the line

Area of Ram (inches2) X Hydraulic Pressure (psi)

Press Capacity (tons) = 2000 (pounds/ton)

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Compression Machines
Compression Molding vs Injection Molding
Compression Molding
• Heated mold
• All plastic material
• Long cycle time (minutes)
• Can’t recycle flash or
waste parts
• Low part complexity
• No undercuts
• No sprue or runners
• Reinforcement material
can be long (inches)
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Injection Molding
• Cooled mold
• Thermoplastic material
• Short cycle time
(seconds)
• Can reprocess flash and
waste parts
• High part complexity
• Undercuts are possible
• Uses sprue and runners
• Some reinforcement
material possible, must
be short (whisker length)
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Products
 Many types of
products in
different
morphology, sizes,
more than one
color per one
product.
 A complex
morphology require
a pre-form similar
to mold before
compress
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Compression Molded Parts

Mold

Part

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Compression Molded Parts

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Advantages
• Molds are inexpensive • High volume output
• Labor costs vary • High quality
• Great for large parts surfaces
• Minimum waste • Complex parts
• Dimensional accuracy
• Warping and shrinkage
minimized
• Fast cycle(1-5
minutes)
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Disadvantages
• No delicate pieces
• Uneven parting lines
• High initial investment
• Secondary operations (e.g. trimming)
• Mold depth is limited
• Product consistency

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Considerations
• Mold heating
– Temperature, heating rate and heating method
• Compression rate
• Max compression force
• Curing time
– How long until part can be removed from
mold.
• Mold cooling rate
• Mold cycling rate
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Range of Materials
Thermoset Thermoplastic Elastomers

• Bulk molding • Pellets  Extruded

compound (BMC)
• Sheets
• Sheet molding
compound (SMC) • Extruded
• Unidirectional
tapes
• Woven Fabrics
• Chopped Strands
• Randomly
oriented fabrics
• Preforms 27

Typical Products
• Automotive parts
– Hoods, bumpers, fenders, spoilers, etc.
• Medical equipment
– Caps and plugs to blood separation
machines and ultrasound equipment
• Aerospace
– Electrical connectors to guided missiles

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Rubber compression

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