1. PLASTICS: FORMING PROCESSES
Look for a suitable image corresponding to each formation technique described on the table (see the example on vacuum forming).
For each of the plastic products suggest a suitable shaping or forming method.

2. Plastics forming processes or methods Typical uses
Used for thermoset, or thermoplastic
Description of process
Vacuum forming
Yoghurt pots, Chocolates and biscuit package trays. Shaped food containers and packages. School projects. Commonly used for high volume and one off, or batch production or mass production.
Thermoplastics (Polystyrene, acrylic, polycarbonate).
A heated thermoplastic sheet is pulled down onto a mould or former by a vacuum action.

3. Plastics forming processes or methods Typical uses
Used for thermoset, or thermoplastic
Description of process
Blow moulding
Soft drinks containers, bottles, containers for detergent, washing up liquid bottles. High’ tooling’ costs makes blow moulding unsuitable for small scale production.
Thermoplastics such as HDPE or LDPE, or PET
begins as a blank cylinder which is heated inside a mould. Hot air is pumped into the blank. Or parison causing it to expand into the mould cavity. Generally used for mostly symmetrical, two part moulds.

4. Plastics forming processes or methods Typical uses
Used for thermoset, or thermoplastic
Description of process
Injection moulding
Used for high volume production of complex plastic casings, containers and enclosures for electrical goods. Very expensive, initial ‘tooling’ costs. Unit costs greatly reduced because of high volume production.
Thermoplastics reduced to a liquid state. ABS, HDPE, LDPE, polypropylene, nylon.
A thermoplastic is heated and injected into a cavity where it takes on the form of the cavity in the mould. It cools and is finally ejected from the mould by ejector pins as the mould is opened. Injection moulding allows complex objects such as whole chairs to be moulded in one process.

5. Plastics forming processes or methods Typical uses
Used for thermoset, or thermoplastic
Description of process
Extrusion
Plastic drain pipes, roof guttering, Window frame sections, plastic channelling. Anything that is a prism, or uniform in section.
Thermoplastics
Thermoplastics are heated and plasticised so they can be squeezed through a die or mould.

6. Plastics forming processes or methods Typical uses
Used for thermoset, or thermoplastic
Description of process
calendering
Plastic bags, plastic material for garments. Making flat sheets of thermoplastics to be sold to industry. Can also be used to press a pattern or surface detail into plastics
Thermoplastic
Making different thicknesses of thermoplastics by heating and squeezing it through decreasing sized gaps between powerful rollers.

7. Plastics forming processes or methods Typical uses
Used for thermoset, or thermoplastic
Description of process
Compression moulding
Electrical fittings such as plugs and sockets. Cooking pot handles
Thermosets such as urea, phenol, or melamine formaldehyde
A powdered thermoset is heated and compressed into a mould at the same time. Once it is ‘baked’ it is removed.

8. 8 4 5 7 1 2 Seed tray 3 Bottles and containers Loo seat and lid
High volume, one piece, moulded shoe
Lightweight, see through roofing or green house
Bottles and containers 2 5 8
Seed tray
Drill casing components for high volume production 3
Loo seat and lid
Plastic seat for large scale production

9. 9 10 16 19 12 20 13 17 14 11 18 21 15 11 Kitchen work top coverings
Plugs and electrical casings 11 16 19
Prisms or uniform sections
Kitchen work top coverings 12 10
Gear and pulley wheels 20
Small volume production amusement park constructions
Flowerpots 13
Retail display stand
Moulded casings and luggage 17 14 11
Sunglasses
Plastic films 18
Palm pilot or phone casing 21 15
Pan handles
Custom car bodies

10. Pipes and guttering 22 28 25 23 27 29 26 Wheelie bins 24 11 Shoe sole
Prisms or uniform sections
Shoe sole 2 25 23
Disposable food trays
Toothbrush and bristles
Motorcycle helmet 6 27 29
Raincoat and garments 26
Wheelie bins
Biro casing 24