Case Study: Car Bumper

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Question 2 Product: Car Bumper Factors: Cost, waste, most straight forward process, A bumper is manufactured using compression moulding. Compression moulding is ideal when manufacturing products of larger size thus being perfect for something like a bumper. While it has low initial cost, when moulding there will only be little waste. This refers to moulding defects such as flash, these defects are reduced because the material is preheated and also the right amount of material needed can be measured. Apart from saving money due to the fact that no workers will be needed to carry out that job, this in itself is also saving more money due to the decrease in the amount of material needed for the process to be carried out. In general, compression …show more content…

Molten plastic passes through the manifold through the nozzles which fill part of the cavities. Since this system eliminates runners completely recycling and regrinding do not affect the cycle. The 2 main types of hot runner systems are internally heated systems, which give better flow control and externally heated systems which suited to polymers with sensitive thermal variations. The cost for such a system may be an expensive capital investment, however it is more cost efficient and in the long run costs are kept to the least possible. This is because of resin savings (resin consumption is lowered due to no cold runner), energy savings (due to plasticising, cooling and regrinding in cold runner mould), labour savings (due to no re-grinding and trimming), mould cost saving (since it runs faster than a cold runner system, a smaller mould may be used to produce the same amount of production) and injection press costs (due to the runner being already hot and thus no heat will be lost). Moulding defects include 1) Blisters - can be avoided by having the temperature near the gate not too high and by regulating the speed of flow into the

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