The term plastic fabrication is used to describe the process of creating products from plastic materials or composites that contain plastics. Plastic fabrication involves everything from product design to manufacturing and assembly. There are many types of plastic materials, each offering its own unique performance capabilities. These types can be categorized into two groups: thermoplastics and thermosets. Both types are highly malleable and cost-effective to work with, which has led to their widespread usage.

In comparison to working with other materials, plastic offers faster production speeds and is easy to form into a variety of shapes. It also produces lighter-weight components that are more cost-effective to produce and ship. At Dar-Kar, we offer an extensive range of plastic fabrication services, creating parts in virtually any desired size, shape, material, or finish. This page will help you understand the different types of plastics and fabrication techniques, as well as factors to consider when selecting the most suitable material for your project.

Understanding the Types of Plastics

While there are many types of plastics, they can all be categorized into one of two groups: thermoplastics or thermosets. The biggest difference between these two groups is that thermoplastics can be melted and re-molded multiple times without degrading, while thermosets become rigid after they are cured and cannot be remolded. Understanding the differences between thermoplastics and thermosets is an essential first step in selecting the best material for a project.
 

Thermoplastics

Thermoplastics have a molecular structure that allows them to be repeatedly softened and reshaped. They are very easy to mold and can be extruded into fibers, films, and other shapes. There are two subcategories of thermoplastics: those with amorphous structures and those with crystalline structures.

Crystalline thermoplastics have a defined melting point as well as good chemical resistance and strength but are not very impact-resistant. Amorphous plastics melt at a variety of temperatures and are easier to fabricate using thermoforming methods. They offer better impact resistance than crystalline thermoplastics, with less shrinkage and tendency to warp. However, they are more prone to stress cracking.

Examples of thermoplastics include:

  • Polytetrafluoroethylene (PTFE) or Teflon
  • Polyvinyl chloride (PVC)
  • Polypropylene (PP)
  • Polyethylene (PE)
  • Polycarbonate (PC)
  • Polyethylene terephthalate (PET)
  • Polymethyl Methacrylate (PMMA)
  • Acrylonitrile Butadiene Styrene (ABS)
  • Low-density Polyethylene (LDPE)
  • High-density Polyethylene (HDPE)

 

Thermosets

After a thermoset is polymerized, it can no longer be remelted and formed into a new shape. However, they can be cut, machined, and joined using adhesives. Thermosets are strong and durable materials used to create products such as auto and aircraft parts. Examples of thermosets include:

  • Epoxy
  • Melamine
  • Phenolic
  • Polyurethane
  • Polyester
  • Silicone

Plastic Fabrication Techniques for Different Types of Plastics

The most suitable fabrication method for any given project depends on the type of plastic used. While there are many techniques to choose from, the four most popular methods include injection molding, extrusion, vacuum forming, and blow molding.

Injection molding

In this process, melted plastic is injected into a custom mold under high pressure to create a solid finished part. Injection molding creates everything from bottle caps to medical devices and auto components.

Extrusion

During the extrusion process, plastic materials are heated to melting point and then pressed through a shaped hole called a die to create a custom plastic part. This process is suitable for creating high volumes of components with a fixed cross-sectional profile, like straws or hoses.

Vacuum forming

Vacuum forming involves softening sheets of plastic around a mold. Suction is used to tightly configure the plastic sheet into shape. This process creates precise smaller parts in high quantities.

Blow molding

This process creates hollow, thin-walled plastic parts with uniform thickness. Raw plastic is heated until it liquefies and then placed in a shaped mold and injected with air. Blow molding creates plastic bottles, traffic cones, and many other small to medium-sized parts.

Plastic Fabrication Techniques for Different Types of Plastics

The most suitable fabrication method for any given project depends on the type of plastic used. While there are many techniques to choose from, the four most popular methods include injection molding, extrusion, vacuum forming, and blow molding.

  • Injection molding

    In this process, melted plastic is injected into a custom mold under high pressure to create a solid finished part. Injection molding creates everything from bottle caps to medical devices and auto components.

  • Extrusion

    During the extrusion process, plastic materials are heated to melting point and then pressed through a shaped hole called a die to create a custom plastic part. This process is suitable for creating high volumes of components with a fixed cross-sectional profile, like straws or hoses.

  • Vacuum forming

    Vacuum forming involves softening sheets of plastic around a mold. Suction is used to tightly configure the plastic sheet into shape. This process creates precise smaller parts in high quantities.

  • Blow molding

    This process creates hollow, thin-walled plastic parts with uniform thickness. Raw plastic is heated until it liquefies and then placed in a shaped mold and injected with air. Blow molding creates plastic bottles, traffic cones, and many other small to medium-sized parts.

Applications of Different Plastics in Plastic Fabrication

As one of the world’s most widely used materials, there are a vast number of applications for plastic fabricated products. At Dan-Kar, we meet the needs of diverse industries with custom-fabricated plastic components. The plastic parts we produce are used in medical applications, as well as automotive, construction, and more.

Automotive industry: Plastic components meet the automotive industry’s need for fuel-efficient, lightweight yet durable components. Many parts previously made using metal perform better using plastic materials.

Construction industry: Plastic fabrication for the construction industry creates customized, high-quality building materials, such as windows, doors, siding, piping systems, and other components.

Consumer goods industry: A huge number of consumer goods are made using plastics since they are cost-effective to produce as well as durable, recyclable, and highly customizable. Everything from toys to outdoor furniture, garden hoses, and much more can be made using plastic materials.

Medical industry: Everything from heart valves to sutures, blood bags, catheters, and much more are made using plastic materials. These items are cost-effective to produce, bacteria-resistant, and disposable.

Packaging industry: Plastic bags, bottles, and boxes are used to package and transport goods reliably and cost-effectively.

Plastic Fabrication Services from Dan-Kar

With over 40 years of industry experience, Dan-Kar offers customer-focused plastic fabrication services for specialty and niche markets. We manufacture everything from micro-sized to large parts in both high and low volumes. Since we work with all types of polymers, we’re able to create high-performing products for nearly any application. To get started on your order, request a quote today.