Have you ever been curious about what products are made with compression moulding? This blog post will highlight different products manufactured using compression moulding. We will also discuss how what compression moulding is, why compression moulding is effective and how our specialised team of engineers can help.
You will be surprised at how many different products are created through the process of compression moulding.
What is compression moulding?
Compression composite moulding is the result of a chemical change of raw material, such as Phenolic, BMC/DMC, SMC, Melamine or Urea Epoxy, as a result of applying heat and pressure, to the material in the mould tool.
The mould tool is closed onto the material charge. The heat of the instrument is between 130C to 180C, which causes the resins in the material to become viscous, allowing the material to flow, which under the hydraulic press pressure, fills the tool mould form. The combination of both heat and pressure, results in a one-way chemical reaction, over the processing time. This process results in a fully hardened and cured moulded product at the point of ejection from the mould tool. The processing time is based on the known cure rate of the material per millimetre of the thickest product section. When ejected from the mould tool, products are the same temperature as the mould tool, which means they require careful handling by an experienced press operator.
What products are made?
All well known Melamine kitchenware and decorative trays are made from compression moulding. The same material is also used for the Cheese Boards behind every deli counter. It is also used in industrial fuse protection systems, as it can be coloured for identification of the wiring system. Hard toilet seats and covers are manufactured in Urea material, as it offers a smooth wipe-clean surface, resistant to chemicals and is warm to feel.
Structural parts for metal replacement are manufactured with compression moulding as well. These parts offer a clean surface, are self-coloured and are impervious to water and oil.
Other uses of compression moulding include creating parts for engine cylinder covers, integral covers for commercial macerators, electrical termination boxes, rail insulators, rail seat back’s, instrument doors and cases and drainage water gratings. These are only a select few of the applications that Merriott Group provide to many industrial customers.
Why is compression moulding effective?
Compression composite mouldings are used in many high voltage electrical applications, as it offers complete insulation, is very strong for structural integration into the end equipment/application. Other benefits include being highly heat resistant, and extremely stable over a wide temperature range.
Compression composite mouldings do not twist, warp, expand/contract due to temperature (creep resistance). This process also has very high fire resistance properties and low smoke emissions. They can eliminate/reduce machining operations when compared to a metal part, no electrical tracking, and in-mould of metal threaded fixings. Overall this process offers designers a wide range of opportunities to review the total cost of their end product.
Mould tools are manufactured using high-quality steels. This steel can either be a high polish finish for low volume applications, chrome-plated for improved wear resistance and in some cases to suit the product material or fully hardened for higher volumes and intricate technical mouldings.
Product volumes can be as low as required or as high as necessary for the end product/application. Many compression composite mouldings have a very long product life, as they designed and manufactured to endure the rigours of the end product application. Pricing of mouldings is therefore subject to the material specification and product demand of the customer.
Our specialised team
At Merriott Group provide a specialist compression moulding service to our clients. Our team can produce composite moulded components that range from a few grams to up to 10 kilos in weight. Our UK based manufacturing process means we can minimise costs while providing quality parts for businesses. Our range of presses ensures that we equipped to meet your needs, especially with presses ranging in clamp tonnage from 20 to 450t.
If you are looking for a high-quality compression moulding service, our experienced team are happy to help. If you are interested in our compression moulding service, get in contact with our team today.