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MANUFACTURING AN ALTERNATIVE DESIGN THROUGH INJECTION MOULDING

V. Ryan 2011-2017

 

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The alternative design is manufactured from PVC (polyvinylchloride).

PVC has been chosen because of its availability in a range of colours.

 
 
 
 
The main casing is in two parts and they have been manufactured through a process called injection moulding.
 
The two main parts interlock to form the entire body. The electronic components, such as speakers and the control circuit, are added later.
 
 
INJECTION MOULDING OF THE MP3 STATION CASING

1. A precise steel mould is manufactured. This will form the shape of the casing, when filled with PVC (polyvinylchloride). The mould is in two parts (called a split mould). When locked together, they form the shape of the casing.

PVC granules are fed into a ‘hopper’. They then fall onto a turning screw thread, which forces then into a heated section.

2. The split mould is closed, forming the shape of the MP3 station casing. The granules heat up and melt as they travel along the screw thread.

3. The molten PVC is forced into the mould, forming the casing shape. It is allowed to cool slightly and is removed from the split (two part) mould.
 
4. Excess PVC is removed by hand using a small saw and rough edges are ‘smoothed’ with a hand file.
 
 
 
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PROPERTIES OF MATERIALS
1. Properties of Materials - 1
2.Properties of Materials - 2
 
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