Deflashing Polystyrene Molded Parts

Introduction

Polystyrene is a synthetic polymer made from the monomer styrene. It is a widely used thermoplastic material that is known for its versatility, low cost, and excellent insulation properties. Polystyrene can be manufactured in a variety of forms, including rigid foam, transparent plastic, and disposable containers.

Polystyrene foam is commonly used for insulation in construction, as well as for packaging materials for delicate items. It is also used to create disposable cups, plates, and other food service items. In its transparent form, polystyrene is often used for items such as CD cases and laboratory equipment. While polystyrene has many useful properties, it is also known for its negative impact on the environment, as it is not biodegradable and can persist in the environment for hundreds of years if not disposed of properly.

Molding Polystyrene

Polystyrene can be molded into various shapes using different methods. The two most common molding methods are injection molding and foam molding.

Injection molding is a manufacturing process where melted polystyrene is injected into a mold under high pressure to produce complex shapes with precise dimensions. This method is typically used for creating solid, rigid objects such as computer housings, car parts, and toys.

Foam molding is a process where polystyrene beads are expanded by steam or other gases and fused together to create a foam. This foam can then be molded into various shapes by using molds of different sizes and shapes. This method is commonly used for making insulation boards, packaging materials, and disposable containers.

In both methods, the polystyrene material is first heated to a molten state, then injected or expanded into the mold. The mold is then cooled to allow the material to solidify into the desired shape. The final product can then be removed from the mold and finished as needed, such as trimming excess material or adding surface texture.

Applications of Polystyrene

Polystyrene is a versatile material that is used in a wide range of applications due to its low cost, insulating properties, and ease of molding. Some common applications of polystyrene include:

1. Packaging materials: Polystyrene is commonly used for packaging materials such as foam peanuts, cushioning pads, and protective containers.
2. Disposable food service items: The material is used to make disposable cups, plates, and utensils due to its low cost and convenience.
3. Insulation: In its foam form it is used for insulation in construction and in the manufacturing of refrigerators, freezers, and other appliances.
4. Medical equipment: Polystyrene is used to create medical equipment such as Petri dishes, test tubes, and pipettes due to its transparency and ability to be sterilized.
5. Toys: This material is used in the manufacturing of toys and hobby models due to its ease of molding and low cost.
6. Electronic products: Polystyrene plastic is used in the manufacturing of electronic products such as computer housings and televisions due to its insulating properties.
7. Automotive parts: Polystyrene is used to make automotive parts such as dashboards, grilles, and exterior trim components due to its lightweight and durability.

Cryogenic Deflashing

Polystyrene can be cryogenically deflashed to remove flash and burrs from molded parts. Cryogenic deflashing is a process that involves exposing the parts to gaseous nitrogen to freeze the flash and burrs, then uses a media blasting mechanism to remove the undesirable frozen material.

This method is effective for removing flash and burrs from intricate or delicate parts that cannot be easily removed using other methods. It is also a non-abrasive method that can help preserve the surface finish of the parts.

Want to send in your polystyrene parts for a no-cost deflashing evaluation? Contact us at (508) 459-7447×105 or email us at info@nitrofreeze.com to learn more.