PLASTIC AND

SYNTHETICS
BY: BALBUENA, SHARUHRAH S.
MATANGUIHAN, JIMUEL M.
MORENO, ENZO
NIBAY, EUGENE IVAN P.
PANGANIBAN, LIAH Y.
RAMOS, CHRIZELLE ANGELIE V.
BS ARCHITECTURE 2-1
CONTENTS
 What is Plastics and  Properties of Plastics
Synthetics?

 History of Plastic  Manufacturing process

of Plastics
 Plastic as construction material

 Advantages and
 Plastic in Architecture
Disadvantages of Plastics
WHAT IS PLASTIC
AND SYNTHETICS?
BY: RAMOS, CHRIZELLE ANGELIE V.
BS ARCHITECTURE 2-1
• Plastic is a general name given to a wide range of synthetic materials that
are based on polymers. The construction industry uses plastic for a wide
range of applications because of its versatility, strength-to-weight ratio,
durability, corrosion resistance.
• Plastics in construction are mainly used for seals,
profiles (windows and doors), pipes, cables, floor
coverings, and insulation. Potentially, plastics have
further use as they do not rot, rust or need regular
re-painting, they have strength with lack of weight,
they are easily formable, and their light weight
enables them to be easily transported and moved on
site.
• Synthetic construction
materials are those that
are manufactured and go
through a lot of human
manipulations.
• This term refers to a whole that is made by
combining two or more parts and, in particular, is
man-made rather than naturally occurring.
Usually involves causing a chemical reaction
between two or more compounds, as in the
creation of most polymers (a group that includes
all plastics and rubbers). In this case, the
compounds being combined are monomers, which
join together to form polymers
REFERENCE
• https://www.designingbuildings.co.uk/wiki/Plastic_in_construction
HISTORY OF
PLASTIC
BY: BALBUENA, SHARUHRAH S.
BS ARCHITECTURE 2-1
THE INVENTION OF PLASTIC
• While we think of plastic as a 20th-century material, natural plastics such as horn, tortoiseshell, amber, rubber and
shellac have been worked with since antiquity.
• Animal horns, malleable when heated, were used for many purposes and products, from medallions to cutlery. The
comb-making industry was one of the biggest applications of horn in the 19th century. 

• IVORY – hard yellowish-white that form the tusks of some animals such as elephants
- used in the past to make decorative

By the middle of the 19th century, in the wake of

industrialized goods production, some animal-derived
materials had become increasingly scarce. Elephants
were facing extinction if demand for their ivory, used in
items from piano keys to billiard balls, continued. The
same fate awaited some species of turtle, whose shell
was harnessed for combs.
 ALEXANDER
PARKES
It was 1862 that Alexander Parkes introduced the world’s first-ever man-made plastic, at
the London International Exhibition

 
• “Parkesine” as it was called, was marketed as an alternative to ivory and horn that Parkes
discovered while trying to develop a synthetic substitute for shellac for waterproofing.

• Parkesine - made from a mixture of chloroform and castor oil, was “a substance hard as
horn, but as flexible as leather, capable of being cast or stamped, painted, dyed or carved.”
THE FIRST SYNTHETIC
PLASTIC
• The material (Parkesine) didn’t start to truly show
its potential value and diversity of applications
until John Wesley Hyatt in Albany, New York
discovered a way to manufacture an improved
version of Parkesine, most commonly known as
celluloid.

• Celluloid is derived from cellulose and alcoholized

camphor. John Wesley Hyatt invented celluloid as
a substitute for the ivory in billiard balls in 1868.
• The first synthetic polymer was invented in 1869 by John Wesley Hyatt, who was
inspired by a New York firm’s offer of $10,000 for anyone who could provide a
substitute for ivory. 
• The growing popularity of billiards had put a strain
on the supply of natural ivory, obtained through the
slaughter of wild elephants. By treating cellulose,
derived from cotton fiber, with camphor, Hyatt
discovered a plastic that could be crafted into a
variety of shapes and made to imitate natural
substances like tortoiseshell, horn, linen, and ivory.

• Besides billiard balls, celluloid became famous as

the first flexible photographic film used for still
photography and motion pictures. Hyatt created
celluloid in a strip format for movie film. By 1900,
movie film was an exploding market for celluloid.
• Only Nature can supply so much
wood, metal, stone, bone, tusk, and
horn.
• But now humans could create new materials. This development helped not
only people but also the environment.

• Advertisements praised celluloid as the savior of the elephant and the

tortoise.

• Plastics could protect the natural world from the destructive forces of
human need.

• “When people refer to plastics, they are referring to synthetic materials.”

THE DEVELOPMENT OF NEW PLASTICS
LEO BAEKELAND

In 1907
Baekeland
Bakelite, Leoinvented
the first fully
synthetic
meaning
no plastic,
it
molecules contained
found in
nature.  But why?
• Celluloid
highly was
flammable
which made
• production
So Baekeland
combined
risky.
Phenol
and
new formaldehyde
creating a hardy
polymer called
Bakelite.
• Baekeland had been searching for a synthetic substitute for shellac, a natural electrical insulator, to meet the needs of
the rapidly electrifying United States. Bakelite was not only a good insulator; it was also durable, heat resistant, and,
unlike celluloid, ideally suited for mechanical mass production.

• World War II necessitated a great expansion of the plastics industry in the United States, as industrial might proved as
important to victory as military success. The need to preserve scarce natural resources made the production of synthetic
alternatives a priority. Plastics provided those substitutes.

• Nylon, invented by Wallace Carothers in 1935 as a synthetic silk, was used during the war for parachutes, ropes, body
armor, helmet liners, and more. Plexiglas provided an alternative to glass for aircraft windows.

• During World War II plastic production in the United States increased by 300%.

• The surge in plastic production continued after the war ended. After experiencing the Great Depression and then World
War II, Americans were ready to spend again, and much of what they bought was made of plastic.

• According to author Susan Freinkel, “In product after product, market after market, plastics challenged traditional
materials and won, taking the place of steel in cars, paper and glass in packaging, and wood in furniture.”
TIMELINE OF THE
PLASTIC
• 1907 – Bakelite

• 1920 – Polystyrene (spongy plastic used for isolation)

Polyvinly Chloride (flexible yet hardy)

Acrylics – transparent shatterproof panels that

mimicked glass

• 1930 – Nylon (took centre stage, polymer designed to mimic

silk but with many times its strength

• 1933 – Polyethylene became one of the most versatile plastics.

PLASTICS IN
ARCHITECTURE
BY: NIBAY, EUGENE IVAN P.
BS ARCHITECTURE 2-1
PLASTIC IN
ARCHITECTURE
The term PLASTICS is essentially a commercial classificatio nto which no strict

scientific definition can be applied. It is used to describe a product of synthetic
origin which is capable of being shaped at some stage of it manufacture, but is not
rubber, wood, leather or metal.

 It is made from a number of common substances such as coal, salt, natural gas,
cotton, wood and water, from which relatively simple chemicals known as
monomers are built up into chain-like molecules of high molecular weight called
polymers.

 Plastics can be hard, soft, clear, opaque, light, heavy, heat resistant or easily softened
by hot water.
-Next page (INSERT VIDEO)
Video about condensation polymerization can be watched on:
https://www.youtube.com/watch?v=-d14DmSBuAQ&t=48s
CLASSIFICATIONS OF
PLASTICS
Classifications of Plastics

a) Cellulose plastics
b) Synthetic resin plastics
c) Plastics derived from proteins and natural resins

Synthetic Resin Plastics are subdivided into 2 classes:

Synthetic Resin Plastics are subdivided into 2 classes:

a) THERMOPLASTICS - Thermoplastics soften when heated and hardens

when cooled regardless of the number of times the process is repeated.
They have a molecular structure which is essentially linear or thread-like in
form.

Examples of Thermoplastics
1) Acrylics – this material combines the
transparency of glass (but not scratch-proof
quality) with plastics’ shatterproof quality.
Used principally for skylights, domes,
safety glass, paints, adhesives, finish
hardware lighting fixtures.
2) Polyethylene (PE) – has 2 types:

 Ziegler PE - is a hard, strong, tough and rigid thermoplastic for household and industrial
applications.

 ICI PE – developed by Imperial Chemical Industries of Britain is a high-pressure, low-

density PE that is flexible, tough and slightly resilient thermoplastic used in construction as
pond or lagoon lining, and water-vapor barriers and damp-proofing.

3) Polystyrene – although sensitive to solvent action, it is

one of the most important thermoplastics because of its excellent
transparency and rigidity and its easy moldability. It is non-water
absorbent, it is found in colorful, but brittle wall tiles. It is one of
several plastics used in lighting fixture diffusers. In foam form,
it has become an important thermal insulator. Also found in paint
for concrete
4) Polyvinyl Chloride (PVC) – is a largely
amorphous, rigid, tough, solvent-resistant, flame-
resistant thermoplastic. Used for resilient floor
tile, films, pipes, and for paint lacquers,
adhesives and safety glass.

5) Polycarbonates – a family of linear

polyesters, is a white, substantially amorphous,
very tough and strong material with good heat
resistance up to 150° C and excellent
dimensional stability. It is injection-molded to
produce plates, rods, gears, and other shaped
parts that advantageously replace die-cast metal
parts.

6) Polypropylene – tough plastic with good

resistance to heat and chemical action.
7) Nylons – “nylon” refers to a family of
polymers called linear polyamides. It is desired
for the following properties: exceptionally
strong, elastic, abrasion resistant, easy to wash,
resistant to damage from oil and many
chemicals, can be precolored or dyed in wide
range of colors, and resilient .

8) Fluroplastics – are a class of paraffinic

polymers that have some or all of the hydrogen
replaced by fluorine. This group is
characterized by excellent chemical resistance,
excellent heat resistance, good electrical
properties, and excellent wear resistance
9) Acrylonitrile butadiene
styrene (ABS) – is a styrenic
resin with improved toughness
and heat resistance. ABS exhibits
high gloss, low shrinkage, and
good dimensional stability, is
widely used in injection molding
of appliances, furniture, and
automotive parts.
b) THERMOSETTING PLASTICS - Thermosetting
plastics, sometimes called thermocuring plastics, set into shape
permanently when heat and pressure are applied during the
forming stage. They have a molecular structure in a 3-
dimensional arrangement.

Examples of Thermosetting Plastics

1) Melamine and Urea – hard, durable, and
dimensionally stable, these similar plastics are resistant to
chemicals, electric potential, and heat.
2) Epoxy – used in buildings for its remarkable adhesive qualities. It may
also be used for special paints that are chemically resistant and for special
caulking compounds.

3) Alkydes – appear chiefly as molded electrical parts, and as the vehicle in

paints, lacquers, and enamels.

4) Phenolics – used for paints,

baked enamels, adhesives,
impregnating resins for paper and
wood, and finish hardware.
5) Polyester – the plastic most
commonly used in large glass-fiber
reinforced translucent panels that are
strong, rigid, and impact-resistant. Also
used for impregnating paper and wood,
as laminating material, and for contact
adhesive.

6) Urethanes – used in paint coatings,

and as foams, are self-adhesive.
7) Plastic Sheets, Film, and Foam
a.) Sheets - usually made of acrylate, polyester, or
polystyrene plastics, either plain or reinforced with
glass-fiber, are available in flat or corrugated sheets and
various deformed shapes. Thicknesses vary from 1.5
mm to 2.38 mm

b) Film – used as a water barrier or damp-proofing

material, it is generally made of polyethylene and
polyvinyl and come in thicknesses ranging from 1 to 10
mils (0.001 to 0.01 inch) and in rolls of 50’ length and
3’ to 40’ width.

c) Foam – used as flotation material, thermal,

insulators, and shock-resistant mountings. It also offers
possibilities for lightweight materials of high strength.
8) Plastic Laminates

• is a composite building material made from kraft paper, resin, and adhesives.

•  Plasticlaminates are usually various layers of material held together by some sort
polymer or plastic material. Laminates are also primarily made in to flat sheet or
tubes and rods .
 EXAMPLES OF STRUCTURES THAT USED PLASTICS

The National Aquatics Center (Water Cube) in Beijing

The National Aquatics Center, also known as the 'Water Cube', was one of the most dramatic and
exciting sporting venues constructed for the 2008 Beijing Olympic Games. Enclosed within the
bubble walls are five swimming pools (including a wave machine and rides), a restaurant and seating
and facilities for 17,000 spectators.
About ETFE (Ethylene tetrafluoroethylene)
• About 20% of the solar energy falling on the building is trapped within it and used to heat the
swimming pools and the interior area.

• The translucent and recyclable ETFE panels ensure the center is well lit during the day with appropriate
levels of internal daylight, visual connection and visual comfort. Up to 55% savings on lighting energy
use are achieved in the leisure pool hall.

• To reduce the energy consumption of the center further, the design has incorporated many energy
recovery systems, such as heat recovery from warm exhaust air for warming up the cold outside air
(fresh air supply).

• Since Beijing suffers from water shortage, water conservation was also central to Arup’s design
philosophy. The firm proposed the reuse and recycling of 80% of water harvested from the roof
catchment areas, pool backwash systems and overland flows. These aim to reduce the reliance and
pressures on local receiving waters and the municipal water supply system by discharging directly to
the sewer system.
Plastic House in Dublin
• The house is on a terrace whose split
section is native to Georgian Dublin; a
grand parlor to the front with smaller
rooms the rear at half-levels one up and
one down from the street.
INTERIOR LOOKS
 The Blur Hotel in
Beijing
• The Blur Hotel, located on the site of a
large government office beside the
western Gate of the Forbidden City, is an
experiment in “urban acupuncture”. As a
refurbishment proposal, the project aims
to harmonize the existing building with
its surroundings and provide a beacon
for renewal of the surrounding area.
 Tony’s Farm in
Shanghai
• Tony’s Farm by Studio Playze is an organic
farm located in Shanghai, China. This
sustainable structure is composed of
upcycled green shipping containers which
make up the lobby as well as multiple
common areas.
Architecture Research
Center at the
University of Nicosia
• The envelope of the building is treated with
polycarbonate panels in various soft color tones
which transmit a controlled, pleasant light
condition in the interior of the building. It is
planned to be accomplished in the near future with
a shading proposal with mesh and climbing
vegetation, designed by Petros Konstantinou and
Yiorgos Hadjichristou Architects.
 The 2015 
Serpentine Gallery P
•
avilion
Consisting of a minimal steel frame wrapped in multi-
colored ETFE sheets and webbing, the design is
encompassed by "secret corridors" which provide
access to the main internal space, inspired by the multi-
layered and sometimes chaotic network of the London
underground.
REFERENCES
 https://www.architecturaldigest.com/gallery/innovative-plastic-buildings

 https://www.arup.com/projects/chinese-national-aquatics-center

 https://www.archiseek.com/2011/2010-plastic-house-dublin/

 https://www.thecoolist.com/tonys-farm-in-shanghai-by-studio-playze/

 https://www.archdaily.com/195083/architecture-research-center-petros-konstantinou-yiorgos
 -hadjichristou

 https://www.archdaily.com/645194/selgascano-s-2015-serpentine-gallery-pavilion-opens
PROPERTIES OF
PLASTICS
BY: PANGANIBAN, LIAH Y.
BS ARCHITECTURE 2-1
• APPEARANCE - In the market there are so many types of models of plastics are available such as transparent, colored
etc. suitable pigments are added in the process of manufacturing of plastic material to get these different properties. So,
these will give good appearance to the structure and makes it attractive.
• CHEMICAL RESISTANCE - Plastics offer great resistance
against chemicals and solvents. Chemical composition of plastics
during manufacturing will decide the degree of chemical
resistance.

• DIMENSIONAL STABILITY - Thermo-plastic types of

plastics can be easily reshaped and reused. But in the case of
thermo-setting type plastics, it is not possible to reshape.

• DUCTILITY - Ductile nature of plastic is very low. When

tensile stress are acting on plastic member they may fail without
any prior indication.

• DURABILITY - Plastics with sufficient surface hardness are

having good durability.
• ELECTRIC INSULATION - Plastics are good electric insulators. So they are used as
linings for electric cables and for electronics tools.

• FINISHING - Any type of finishing treatment can be given to the plastics.

• FIRE RESISTANCE - The resistance to temperature or fire for varieties of plastics

considerably varies depending upon the structure. Plastics made of cellulose acetate are
burnt slowly. PVC made plastics do not catch fire easily. Plastics made of phenol
formaldehyde and urea formaldehyde are fire proof materials.
• FIXING - Fixing of plastic materials is so easy. We can bolt, drill or glued to fix plastic
material position.

• HUMIDITY - The plastics made up of cellulosic materials are affected by the presence of
moisture. The plastics made of poly vinyl chloride (PVC pipes) offers great resistance
against moisture.
• MAINTENANCE - Maintaining of plastics are so simple. Because they do not need
any surface finishing coats or paints etc.

• MELTING POINT - Generally plastics have very low melting point. Some plastics
may melt at just 50oC. So, they cannot be used in the positions of high temperature.
Thermo setting type of plastics are having high melting point than thermo plastic type
plastics. However, thermo setting types are cannot used for recycling. To improve the
heat resistance of the plastics, glass fiber reinforcement is provided in its structure.

• OPTICAL PROPERTY - There are so many types of plastics. Some plastics are
transparent which allows light in its original direction and some are translucent
nothing but semi-transparent which allows light but changes light rays direction.  

• RECYCLING - Disposal of plastics in the environment causes severe pollution. But it

is not a serious problem because of its recycling property. We can use plastic waste
disposal conveniently to produce drainage pipes, fencing, hand rails, carpets, benches
etc.

• SOUND ABSORPTION - By the saturation of phenolic resins we can produce

acoustic boards. These acoustic boards are sound absorbents and provide sound
insulation. Generally for theatres, seminar halls this type of acoustic ceilings are used.
 • STRENGTH - Practically we can say that plastic is strong material but ideal section of
plastic which is useful for structural component is not designed yet. Generally by
reinforcing fibrous material into plastic improves its strength.

• THERMAL PROPERTY - The thermal conductivity of plastics is very low and is

similar to wood. So, foamed and expanded plastics are used as thermal insulators.

• WEIGHT - The Plastics have low specific gravity generally ranges from 1.3 to 1.4.
So they are light in weight and easily transportable to any place in a large quantity.

• WATER RESISTANCE - Most of the plastics except some limited varieties are capable of resistance against weathering. But,
major problem is plastics when the plastics are exposed to sunlight, they are seriously affected by ultra violet rays and gets brittle.
To prevent this, plastics are incorporated by fillers and pigments which helps to absorb or reflect the UV rays to surface.

• WEIGHT - The Plastics have low specific gravity generally ranges from 1.3 to 1.4. So they are light in weight and easily
transportable to any place in a large quantity.
REFERENCE
 https://theconstructor.org/building/plastics-construction-material/12438/
MANUFACTURING
PROCESS OF PLASTIC
BY: RAMOS, CHRIZELLE ANGELIE V.
BS ARCHITECTURE 2-1
 THIS GUIDE PROVIDES AN OVERVIEW OF THE MOST COMMON MANUFACTURING PROCESSES
FOR PRODUCING PLASTIC PARTS AND GUIDELINES TO HELP YOU SELECT THE BEST OPTION FOR
YOUR APPLICATION.

MANUFACTURING PROCESS

 3D Printing  Vacuum Forming

 CNC Machining Injection Molding

 Polymer Casting Extrusion

 Rotational Molding Blow Molding

3D PRINTING
• 3D printers create three-
dimensional parts directly from
CAD models by building
material layer by layer until a
complete physical part is
formed.
Stereolithography (SLA)
-Next page (INSERT VIDEO)
Video about 3D Printing can be watched on: https://www.youtube.com/watch?
v=8a2xNaAkvLo&feature=emb_imp_woyt
 MANUFACTURIN
G PROCESS
1. Print setup: Print preparation software is used for orienting and laying out
models within a printer’s build volume, adding support structures (if needed),
and slicing the supported model into layers.

2. Printing: The printing process depends on the type of 3D printing technology:

fused deposition modeling (FDM) melts a plastic filament, stereolithography
(SLA) cures liquid resin, and selective laser sintering (SLS) fuses powdered
plastic.
3D PRINTED PRODUCT
3. Post-processing: When printing is complete, parts are removed from the printer,
cleaned or washed, post-cured (depending on the technology), and the support
structures removed (if applicable).
 As 3D printers require no tooling and minimal setup time for a new
design, the cost of producing a custom part is negligible in
comparison with traditional manufacturing processes.

3D printing processes are generally slower and more labor-intensive

than manufacturing processes used for mass production.

As 3D printing technologies improve, cost per part continues to fall,

opening up a wider range of low- to mid-volume applications.
CNC (COMPUTER
NUMERICAL
CONTROL)
MACHINING
•CNC machining includes mills, lathes, and
other computer-controlled subtractive
processes. These processes start with solid
blocks, bars, or rods of metal, or plastic that are
shaped by removing material through cutting,
boring, drilling, and grinding.

-Next page (INSERT VIDEO)

Video about CNC can be watched on:
https://www.youtube.com/watch?v=-Qn-KCU4cWU
MANUFACTURING
PROCESS
1. Job setup: CNC machines require an intermediary step of generating and validating toolpaths (CAD
to CAM). Toolpaths control where the cutting tools move, at what speeds, and any tool changeovers.

2. Machining: The toolpaths are sent to the machine where the given subtractive process begins.
Depending on the desired shape of the final product, the workpiece may need to be set in a new
position so that the tool head can reach new areas.

3. Post-processing: After manufacture, the part is cleaned and deburred, trimmed.

Machining is ideal for low volume plastic part applications that require tight
tolerances and geometries that are difficult to mold. Typical applications include
prototyping and end-use parts like pulleys, gears, and bushings.

Machining processes have more part geometry restrictions than 3D printing.

With machining, cost per part increases with part complexity. Undercuts, pass
throughs, and features on multiple part faces all contribute to increased part cost.

Machining processes require allowances for tool access and certain geometries,
like curved internal channels, are difficult or impossible to produce with
conventional subtractive methods.
POLYMER
CASTING
• In polymer casting, a reactive
liquid resin or rubber fills a mold
which reacts chemically and
solidifies. Typical polymers for
casting include polyurethane,
epoxy, silicone, and acrylic.

-Next page (INSERT VIDEO)

Video about Polymer Casting can be watched on:
https://www.youtube.com/watch?v=m0pv3kDKynQ
MANUFACTURING PROCESS
1. Mold preparation: The mold is coated 4. De-mold: The mold is opened and
with a release agent to facilitate demolding, the cured part is removed.
and often preheated to a material specific
temperature.
5. Trimming: Casting artifacts like
2. Casting: The synthetic resin is mixed with flash, sprues, and seams are cut or
a curing agent and poured or injected into the sanded away.
mold, where it fills the mold cavity.

3. Cure: The casting cures in the mold until

it solidifies (subjecting the mold to heat can
accelerate the cure time for certain polymers).
Flexible molds made from latex rubber or room temperature vulcanized (RTV)
silicone rubber are inexpensive when compared to hard tooling, but can produce
only a limited number (around 25 to 100) of castings as the chemical reaction of
urethanes, epoxies, polyester, and acrylic degrades the mold surfaces.

Polymer casting is relatively inexpensive, with little initial investment, but

thermoset polymers for casting are usually more expensive than their
thermoplastic counterparts and molding cast parts is labor-intensive. Each cast
part requires some hands-on labor for post-processing, making the final cost per
part high compared to automated production methods like injection molding.

Polymer casting is typically used for prototyping, short run production, as well
as certain dental and jewelry applications.
ROTATIONAL MOLDING
 Rotational molding (also called
rotomolding) is a process that involves
heating a hollow mold filled with
powdered thermoplastic and rotated around
two axes to produce mainly large hollow
objects. Processes for rotomolding
thermoset plastics are available as well,
however less common.

-Next page (INSERT VIDEO)

Video about Rotational Molding can be watched on:
https://www.youtube.com/watch?v=SSFscMv2PKU
MANUFACTURING
PROCESS
1. Charging: Plastic powder is loaded into the mold cavity, and then the remaining parts of the
mold are installed, closing the cavity for heating.

2. Heating: The mold is heated until the plastic powder melts and adheres to the mold’s walls, while
the mold is rotated along two perpendicular axes to ensure a uniform plastic coating

3. Cooling: The mold is slowly cooled while the mold remains in motion to ensure that the skin of
the part does not sag or collapse before fully solidifying.

4. Part removal: The part is separated from the mold, any flashing is trimmed away.
• Rotational molding requires less expensive tooling than other molding techniques as the process uses
centrifugal force, not pressure, to fill the mold. The molds can be fabricated, CNC machined, cast, or
formed from epoxy or aluminum at a lower cost and much faster than tooling for other molding
processes, especially for large parts.

• Rotomolding creates parts with nearly uniform wall thickness. Once the tooling and process are set up,
the cost per part is very low relative to the size of the part. It is also possible to add prefinished pieces,
like metal threads, internal pipes, and structures to the mold.

• These factors make rotational molding ideal for short-run production or as an alternative to blow
molding for lower volumes. Typical rotomolded products include tanks, buoys, large containers, toys,
helmets, and canoe hulls.

• Rotomolding has some design constraints and finished products have looser tolerances. As the entire
mold has to be heated and cooled down, the process also has long cycle times and is quite labor
intensive, limiting its efficiency for higher volume applications.
VACUUM FORMING
• Vacuum forming is a manufacturing
method where a plastic is heated and
formed, typically using a mold. Vacuum
forming machines vary in size and
complexity from low-cost desktop
devices to automated industrial
machinery. The steps below describe the
typical process for industrial vacuum
forming.
-Next page (INSERT VIDEO)
Video about Vacuum Forming can be watched on:
https://www.youtube.com/watch?v=VyIBsmoiqqs
MANUFACTURING PROCESS
1. Clamping: A plastic sheet is clamped in a 4. Cooling and release: Once the part has
frame. been formed over the mold, it must be given time
2. Heating: The sheet and the frame are to cool before removal. Cooling system like fans
moved close to heating elements, which makes and sprayed mist are sometimes used to reduce
the plastic soft and pliable. cycle times.

3. Vacuum: The frame is lowered, and the 5. Trimming: Once the part is released, excess
plastic is stretched over the mold, while vacuum material is cut off either by hand or with a CNC
is activated to suck all the air out from between machine.
the plastic and the mold, thus forming the part.
Tooling costs for vacuum forming are low compared to other molding techniques, due
to low forces and pressures involved. Molds are made from wood, plaster, or 3D printed
resin for short production runs and custom parts. For high production volumes,
manufacturers use more durable metal tooling.

Given the wide scale of thermoforming and vacuum forming machinery available and
the possibilities for automation on the high end, thermoforming is ideal for any
application from custom products or prototypes to mass production. However, the
process offers only limited form freedom and can only be used to manufacture parts with
relatively thin walls and simple geometries.

Commonly vacuum formed parts include product packaging, shower trays, car door
liners, boat hulls, and custom products like dental aligners.
INJECTION
MOLDING
• Injection molding (IM) works by
injecting molten thermoplastic into
a mold. It is the most widely used
process for mass manufacturing of
plastic parts.

-Next page (INSERT VIDEO)

Video about Injection Molding can be watched on:
https://www.youtube.com/watch?v=RMjtmsr3CqA
MANUFACTURING PROCESS
1. Mold setup: If the part has inserts, these are added either by hand or robotically. The mold is closed
by a hydraulic press.

2. Plastic extrusion: Small plastic pellets are melted and extruded through a heated chamber by a screw.

3. Molding: The molten plastic is injected into the mold.

4. Cooling and release: The part cools in the mold until it is solid enough to be ejected, either
mechanically or by compressed air.

5. Post-processing: Sprues, runners and any flash (if applicable) is removed from the part, often
automatically as part of the mold opening.
Molds for injection molding are highly complex and need to be manufactured to tight
tolerances to produce high-quality parts. Due to the high temperature and pressures
involved, these molds are machined from metals like hardened steel. Softer aluminum
molds are less expensive, but also wear faster, so are typically used for more moderate
production runs.

Injection molding can be used to produce highly complex parts, but certain geometries will
increase cost significantly. Following design for manufacturing (DFM) guidelines will help
to keep tooling costs manageable. Creating new molds for injection molding can take
months to complete, and their costs can run into five or six digits.

Despite the high initial costs and slow ramp up, injection molding has no match for high
volume applications. Once the tooling is up and running, cycle times only take a few
seconds, and millions of high-quality parts can be produced at a fraction of the cost of all
other manufacturing processes.
EXTRUSION
Extrusion molding works
by pushing plastic
through a die. The shape
of the die is a cross-
section of the final part.

-Next page (INSERT VIDEO)

MANUFACTURING
PROCESS
1. Plastic extrusion: Plastic is heated and pushed through a heated chamber by a
screw.

2. Molding: Plastic is forced through a die that creates the final shape of the part.

3. Cooling: The extruded plastic is cooled.

4. Cut or spool: The continuous shape is spooled or cut into lengths.

Extrusion machinery is relatively cheap compared to other industrial machines
like CNC or injection molding as it is less complex and does not require such
high levels of machine accuracy. Due to the simple shapes, dies are also less
expensive, with tooling costs that are a fraction of molds for injection molding.

Much like injection molding, extrusion molding is an almost continuous

process, which makes the price of extruded parts very low.

Forms and shapes that can be manufactured with extrusion are limited to
products that have continuous profiles, such as T-sections, I-sections, L-sections,
U-sections, and square or circular sections. Typical applications include pipes,
hoses, straws, and window frame moldings.
BLOW MOLDING
• Blow molding is a
manufacturing technique
used to create hollow
plastic parts by inflating a
heated plastic tube inside a
mold until it forms into the
desired shape

-Next page (INSERT VIDEO)

Video about Blow Molding can be watched on:
https://www.youtube.com/watch?v=NE4c1gwzPb4
MANUFACTURING PROCESS
1. Mold setup: Small plastic pellets are melted and formed into a hollow
tube, called the parison or preform (depending on the blow molding subtype).

2. Molding: The parison is clamped into a mold and gets inflated by

pressurized air until it takes the shape of the inside of the mold.

3. Cooling and release: The part cools in the mold until it is solid enough to
be ejected.
Blow molding operates at far lower pressures than injection
molding, which contributes to a lower tooling cost. Much like
injection molding and extrusion, blow molding is a continuous
process that can be fully automated, resulting in high production
rates and low unit costs.

Blow molding is the most common process for creating hollow

plastic products at scale. Typical applications include as bottles,
toys, automotive components, industrial parts, and packaging.
REFERENCES
https://www.labelplanet.co.uk/glossary/synthetic/

https://www.designingbuildings.co.uk/wiki/Plastic_in_construction

 https://formlabs.com/asia/blog/guide-to-manufacturing-processes-for-plastics/
ADVANTAGES AND
DISADVANTAGES OF
PLASTIC MATERIALS
BY: MATANGUIHAN, JIMUEL M.
BS ARCHITECTURE 2-1
ADVANTAGES OF
PLASTIC
MATERIALS
 COST - One of the main advantages to using plastic as a construction material is the
cost to produce and use plastics

 RESISTANCE - Plastics have a high resistance to corrosion, making them perfect for
use where a metal may start to rust and corrode. Therefore, plastics are the most
common material to construct water pipes out of.

 WEIGHT - Plastic is a very lightweight material compared to many other construction

materials, this gives the material a greater flexibility in its use on site and in
transportation.

 COLOR - Plastics can easily be colored in their manufacturing stage which is a useful
property to have on a building site

 ENVIRONMENT - Plastics high resistance means that no rust will form on plastic
therefore, no rust will seep into the ground or water supply.
DISADVANTAGES OF PLASTIC
MATERIALS
Cheap production and easy availability make plastic very useful, but it has many shortfalls and its harmful
effects are cause of huge concern for us to save our earth and ourselves. Its few disadvantages are listed below
–

 Natural decomposition of plastic can last from 400-1000 years and few types of plastics are non-degradable
as well. 

 Plastic materials clog waterways, oceans, seas, lakes etc. 1 in 3 species of marine mammals have been found
entangled in marine litter. 

 Many animals eat plastic materials and die. Over 90% of all seabirds have plastic pieces in their stomachs. 

 Plastic is not fireproof and burning plastic may pose a serious threat of environmental hazards.

 Both creation and recycling of plastic produce toxic gases and residues which causes air and water and land
pollution
REFERENCES
 https://civilwale.com/types-of-building-materials/

 https://www.rayda.co.uk/blog/advantages-plastics-construction/

 https://www.vedantu.com/chemistry/disadvantages-of-plastics
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LISTENING!!!