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Concept
Transfer molding
Summary
Transfer molding (BrE: transfer moulding) is a manufacturing process in which casting material is forced into a mold. Transfer molding is different from compression molding in that the mold is enclosed rather than open to the fill plunger resulting in higher dimensional tolerances and less environmental impact. Compared to injection molding, transfer molding uses higher pressures to uniformly fill the mold cavity. This allows thicker reinforcing fiber matrices to be more completely saturated by resin. Furthermore, unlike injection molding the transfer mold casting material may start the process as a solid. This can reduce equipment costs and time dependency. The transfer process may have a slower fill rate than an equivalent injection molding process.
The mold interior surfaces may be gel-coated. If desired, the mold is first pre-loaded with a reinforcing fiber matrix or preform. Fiber content of a transfer molded composite can be as high as 60% by volume. The fill material may be a preheated solid or a liquid. It is loaded into a chamber known as the pot. A ram or plunger forces material from the pot into the heated mold cavity. If feed-stock is initially solid, the forcing pressure and mold temperature melt it. Standard mold features such as sprue channels, a flow gate and ejector pins may be used. The heated mold ensures that the flow remains liquid for complete filling. Once filled the mold can be cooled at a controlled rate for optimal thermoset curing.
The industry identifies a variety of processes within the transfer molding category. There are areas of overlap and the distinctions between each method may not be clearly defined.
Resin transfer molding (RTM) uses a liquid thermoset resin to saturate a fiber preform placed in a closed mold. The process is versatile and can fabricate products with embedded objects such as foam cores or other components in addition to the fiber preform.
Vacuum assisted transfer molding (VARTM) uses a partial vacuum on one side of a fiber mat to pull the resin in for complete saturation.
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