Compression

Mould Design
Reporter
 01 Introduction to Compression
Molding

CONTENTS 02 Key Elements of

Compression Mould Design

03 Design Considerations for

Compression Moulding

04 Types of Compression
Moulds

05 Manufacturing Process of
Compression Moulds

06 Troubleshooting Common
Issues
01
Introduction to Compression
Molding
Overview of Compression Molding

01 02 03
Advantages of Limitations of
Definition and Basic Compression Compression
Principle Molding Molding

Compression molding is a Low tooling cost makes it Slower cycle times

closed-mold process economical for short compared to injection
where a polymer production runs; good molding; limited to
compound is squeezed surface finish is relatively simple part
into the mold cavity by achievable; suited for geometries; difficult to
heat and pressure; it's large parts with simple control dimensional
ideal for producing large, geometries; minimal tolerances; flash may
simple shapes with material waste. require post-processing.
uniform thickness.
Common Materials Used

Thermosetting Polymers Elastomers Composites

Thermosets like phenolic resins, Elastomers like natural rubber and Fiber-reinforced composites, such
epoxy resins, and unsaturated silicone rubber are compatible as SMC & BMC, are often
polyesters are commonly used for with compression molding to compression molded because of
their high strength and thermal produce flexible parts; often used their superior strength, electrical
stability. for seals and gaskets. properties, and heat resistance.

01 02 03
Applications of Compression Molding

Automotive Industry Electrical Industry Consumer Products

Production of large, structural Manufacturing of electrical Producing kitchenware,

parts such as hoods, fenders, housings, insulators, and buttons, knobs, and handles
and interior components switchgear components due where the process economics
where high strength, stiffness to thermosets' excellent and material properties are
and heat resistance are electrical insulation beneficial.
required. properties.

01 02 03
02
Key Elements of Compression
Mould Design
Mold Cavity and Core

Importance of Cavity Material Selection for Cavity Surface Finish

and Core Design Cavity and Core

The cavity and core define the Tool steels like P20, H13, and Surface finish is critical as it
shape of the part; precise stainless steel are often directly impacts the
machining and finishing are chosen due to their strength, appearance and release of the
essential to ensure part quality hardness, wear resistance, and molded part; a smooth,
and dimensional accuracy. thermal conductivity. polished surface minimizes
friction and prevents sticking.

1 2 3
Heating System Design

Importance of Temperature
Control

Uniform temperature distribution

ensures consistent curing and
minimizes defects like warpage and Heater Placement
uneven shrinkage.
Heaters should be strategically placed
near the cavity and core to maintain

Heating Methods uniform temperature; consider heat

loss and insulation to maximize
Electrical resistance heaters provide efficiency.
precise control and uniform heating;
steam heating is cost-effective for
large molds; hot oil circulation offers
efficient heat transfer.
Ejection System Design
Ejection Force and Placement
Calculate the required ejection force
based on part geometry, material, and
surface finish; distribute ejection points
Purpose of Ejection System
evenly to prevent distortion or damage.
An ejection mechanism is necessary to
remove the part from the mold without
damage; proper design ensures reliable
and repeatable ejection.

Ejection
Pin ejectionMethods
uses strategically placed pins to push
the part out; stripper plate ejection is suitable for
parts with large surface areas; air ejection can
assist with part removal.
03
Design Considerations for
Compression Moulding
Shrinkage Compensation

Material Shrinkage
01 Thermosets and elastomers shrink as they cool and cure; mold dimensions must be adjusted
to compensate; shrinkage rates can vary.

Shrinkage Factors

02 Shrinkage factors are material-specific and can be obtained from material datasheets or
experimental testing; consider factors like part geometry and molding conditions.

Mold Dimension Calculation

03 Calculate mold dimensions by adding the appropriate shrinkage allowance to the desired part
dimensions; account for tolerances and manufacturing capabilities.
Venting

Importance of Venting

Vents allow air and gases to escape during molding, preventing defects like
voids, porosity, and incomplete filling.

Vent Placement

Place vents at the farthest points from the material entry to facilitate air
escape; vents should be small enough to prevent material from escaping.

Vent Design

Shallow vent channels are machined into the mold surface; vent depth and
width depend on the material and molding conditions.
Flash Control

Flash Removal

Flash Control Methods

Sharp knives and
Flash Formation abrasive tools are used to
Close tolerances between remove flash manually or
mold components using automated
Flash is excess material
minimize flash; land trimming machines;
that squeezes out of the
areas around the cavity consider the cost and
mold cavity; results in
prevent material escape; impact on part quality.
material waste and
proper clamping force is
requires post-processing.
also essential.
04
Types of Compression Moulds
Flash Type Mould

01 Design and Function

02 Advantages

Simplest and most

economical type; excess 03 Disadvantages
material forms a flash Low tooling cost and
around the parting line; design simplicity, suitable
requires additional flash for high-volume
Significant flash
removal. production; easy to
generation and material
manufacture and maintain.
waste; manual flash
removal adds to labor
costs; limited dimensional
accuracy.
Positive Type Mould

Design and Disadvanta

Advantages
Function ges

Material is precisely Minimal material Higher tooling cost

measured and waste and reduced and greater
placed in the cavity; need for flash complexity; material
little or no flash is removal; improved loading and control
generated; requires dimensional are critical; less
tight control of accuracy and tolerant of variations
material volume. surface finish. in material
properties.
Landed Type Mould

Design and Function Advantages Disadvantages

01 02 03

A short vertical land area Balances the advantages and Requires precise land
controls the flow of material disadvantages of flash and dimensions and alignment;
and minimizes flash. positive molds; provides a material viscosity and
compromise for flash control pressure must be carefully
and ease of use. controlled.
05
Manufacturing Process of
Compression Moulds
Design Phase

Simulation and Analysis

01 Utilize FEA software to simulate molding
process; analyze temperature distribution,
stress, and deformation; identify potential
issues.
CAD Modeling
Use CAD software to create a detailed 3D
02
model of the mold components; ensure
accuracy and adherence to design
specifications.
Design for Manufacturability
03 Consider manufacturing processes and
limitations; ensure that the mold design can
be produced efficiently and economically.
Machining and Fabrication

CNC Machining EDM Grinding and Polishing

CNC milling and turning Electrical Discharge Grinding and polishing

machines create complex Machining (EDM) is used to operations achieve desired
mold geometries with high create intricate shapes and surface finish and
precision; ensure proper tool fine details that are difficult to dimensional accuracy; ensure
selection and cutting achieve with conventional proper techniques and
parameters. machining. equipment.

01 02 03
Assembly and Testing

01 02 03
Mold Assembly Mold Testing Final Inspection

Assemble mold Test the mold with the Conduct a final inspection
components carefully; specified material; of the molded parts; verify
verify alignment and fit; monitor temperature, dimensional accuracy,
ensure that all pressure, and cycle time; surface finish, and
components function identify and resolve any absence of defects.
correctly. issues.
06
Troubleshooting Common Issues
Part Defects

Voids and Porosity Warpage and Surface Defects

Distortion

01 02 03

Voids and porosity are caused Non-uniform cooling or Surface defects include
by trapped air or gases; shrinkage can lead to blisters, orange peel, and flow
improve venting and material warpage; optimize cooling marks; control material
flow; increase molding design; use appropriate temperature and flow rate;
pressure. clamping force. optimize mold surface finish.
Moulding Issues

Uneven Heating

Flash
Uneven heating causes
Sticking Parts inconsistent curing;
Excessive flash results optimize heater
from poor mold closure or placement; ensure
Parts sticking to the mold
excessive material; uniform temperature
are due to poor surface
improve mold alignment; distribution.
finish or inadequate
reduce material volume.
ejection; improve surface
finish; optimize ejection
force and placement.
Maintenance and Repair

Regular Cleaning Lubrication Component

Replacement
Clean mold components Lubricate moving parts to Replace worn or damaged
regularly to remove residue reduce friction and wear; use components; monitor mold
and prevent sticking. appropriate lubricants for performance; implement
high-temperature preventive maintenance.
environments.

01 02 03
07
Future Trends in Compression
Moulding
Automation

Implement automated systems for material feeding

Automated Material
01- and part ejection; reduce labor costs; improve
Handling
efficiency and consistency.

Robots can perform tasks such as material loading,

02- Robotic Moulding part removal, and flash trimming; improve
productivity and reduce cycle times.
Advanced Materials

High-Performance Thermosets

Develop thermosets with improved strength, temperature resistance, and chemical resistance;
expand applications in demanding environments.

Nanocomposites

Incorporate nanoparticles into thermosets to enhance mechanical, thermal, and electrical properties;
create new opportunities for compression molding.
Simulation and Optimization
Process Monitoring and Control

Implement real-time process monitoring

and control systems; ensure consistent
quality; reduce scrap; optimize energy
consumption.

Advanced Simulation Tools

Use advanced simulation tools to

optimize mold design and molding
parameters; improve part quality;
reduce defects.
•Thank you
for listening.
Reporter