The Importance and Utilization of Compression Molds
/Manufacturing a high-quality plastic component starts with choosing not only the right type of mold but also choosing a well-built mold that will last and perform. A quality compression mold produces parts that are accurate, efficient, and consistent every time.
There are two common types of molds, injection and compression, which are the most commonly used for making parts. There are also others that aren’t quite as common but still widely used, like blow, transfer, rotational, thermoform, extrusion, and reaction injection molds.
Each type of mold has its advantages to the production process. However, compression molds are used globally for a lot of reasons including being a cost-effective and long-lasting solution.
In this blog we’ll take a look at the specifics of compression molds, why they’re a favorite globally of plastic molding companies, and the positive impact that they can have on a production line.
What are Compression Molds?
A compression mold is typically made of steel or aluminum and are able to form parts from raw materials with high amounts of heat and pressure. Because of their ability to withstand high heat and pressure, compression molds are ideal for forming parts from thermoset materials which are plastics that permanently harden during the curing process. Common thermoset composites used in compression molding include:
Phenolic resin
Epoxy
Melamine
Polyester
While these materials are the most common types of materials used in compression molds, thermoplastic materials can also be used.
Why choose a compression mold?
Compression molds are simple, cost-effective molds for generally large or thick parts which often require durability, insulation, and heat resistance. They form a solid and durable finished part with less material waste than other methods.
Advantages of Compression Molds
Durability and Lifespan: Compression molds are durable and built to withstand high pressure and temperature over long periods of time.
Customization: Can produce heavy-duty parts in a wide range of shapes, sizes, and thicknesses, making them ideal for specialized or performance-driven applications.
Precision: Compression molds are designed to replicate precise components with accuracy
Value: Offer a high return on investment for large production runs, thanks to their durability. Their longer lifecycle can increase line efficiency and help offset some of the initial investment costs.
How does compression molding work?
A compression mold is designed to accept heated material into the mold cavity until it takes shape and hardens. This molding process starts with a pre-determined amount of molding material, in pellets, sheets or putty form that are added directly into the open, heated mold cavity. The mold is then closed and the material is subjected to high pressure, anywhere from 800 to 2000 psi. (add image) This pressure forces the softened material to conform to the details of the mold.
Which Industries use compression molds?
Compression molds are most commonly used in industries that require high-strength parts, such as:
Automotive
Electrical
Medical
These industries choose compression molds as they can create plastics that are stronger and lighter than metal parts while maintaining design complexity. Since the raw material gets packed directly into the mold cavity, compression molds are also ideal for producing larger parts and products without worrying about weight restrictions.
Companies have choices when designing a part from the design to material to the molding. While injection molding may make sense for some parts, there are valid reasons to make the part through compression molding which is why this is a popular choice for companies across the globe. Their design allows the production of durable, high-precision parts that can be made more efficiently than when using other mold types. Compression molds, with proper maintenance and care, are also known to have a long lifespan resulting in less downtime which leads to a decrease in manufacturing costs. Though compression molds can require an upfront commitment, they have a high potential for long-term cost savings.
Factors like material and application should always be considered when deciding what mold type is best suited for a project. If your company is looking at starting a new compression molding project get in touch with the experts at Versatile Mold and Design by calling (706)-557-8397, or visiting our contact page.
