Introduction to Processing

The mechanical properties and the performance of a finished product are always the result of a sequence of events. Manufacturing of a plastic part begins with material choice in the early stages of part design. Then follows processing, which determines the properties of the final part and freezes them into place. During design and manufacturing of any plastic product one must always be aware that material, processing, and design properties all go hand-in-hand and cannot be decoupled. This approach is often referred to as the six P’s: polymer, processing, product, performance, post-consumer life, and profit. This chapter presents the most important polymer processing techniques available today1. Extrusions2 is covered first, followed by mixing processes and injection molding3. Secondary shaping operations are discussed next. At the end of the chapter other processes, such as calendering, coating, compression molding, and rotational molding are presented.