The plastics industry is now such an essential part of modern life that most of us have some idea of how plastic is manufactured, through a process of melting the raw materials and forcing them under pressure through different shaped dies to create the desired shape. Few of us however, think about or understand how flexible PVC extrusions are designed. However, the design is a crucial part of making plastic products and a full understanding of the manufacturing process will not be possible without finding information about how specific dies are designed. The quality of the design determines the end result in any creative process, and plastics are no exception.
Nowadays high quality flexible PVC extrusions are made from a wide variety of materials and are available in multiple combinations of shapes, colours and sizes. All PVC plastic products start with the design but there are a number of variables that need to be considered before proceeding to design anything new.
Good design ensures that the end product will be cost-effective to produce and of uniform quality. From a commercial point of view, these attributes are essential to the success of any product. However, in the manufacture of flexible PVC extrusions, design considerations can be broken down into two parts - basic tie design and part design.
In terms of basic die design, a flat plate die plate has the shape of the part cut through a die and there is no transition to guide the material. This design is low cost and ideally suited to low volume production runs. With respect to a semi-streamlined die, the edges and corners at the back of the die have radii to assist the material flow into the die. A fully streamlined die is able to force the plastic material through the die evenly. This design is expensive and therefore ideally suited to high production runs.
Referring now to part design, a uniform wall thickness is vital to design a successful part as it allows material to flow evenly through the die. The result is more controlled parts and lower tooling costs. Designing profiles with hollow sections should be avoided wherever possible as they add significantly to manufacturing costs, and plastic manufacturers are always looking for ways to reduce costs and increase profits.
Plastics manufacturing isn't necessarily a complicated process, but there are many components to it that require professional expertise and specialised knowledge. The design of the dies is just one aspect, and requires careful selection of methods if the desired result is to be achieved, along with the commercial requirements of high quality and low cost.
At pacific plastic, plastic manufacturers provide you high quality of flexible PVC extrusions are made from a wide variety of materials and are available in multiple combinations of shapes, colors and sizes.
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