MATL07027 2019 Polymer Processing

General Details

Full Title
Polymer Processing
Transcript Title
Polymer Processing
N/A %
Subject Area
MATL - Materials
MENG - Mech. and Electronic Eng.
07 - NFQ Level 7
05 - 05 Credits
Start Term
2019 - Full Academic Year 2019-20
End Term
9999 - The End of Time
Donal Lyons, David Mulligan
Programme Membership
SG_EPLYP_J07 201900 Bachelor of Engineering in Engineering in Polymer Processing

This module will provide the student with a comprehensive knowledge of the principles of operation, construction and layout of equipment used in the melt processing of polymeric materials.

The student will study the relationship between materials, products and process variables.

Learning Outcomes

On completion of this module the learner will/should be able to;


Demonstrate a basic knowledge and understanding of the principles of Rheology.


Demonstrate knowledge, understanding, and practical experience of the extrusion process including compounding, sheet production, and profile production.


Demonstrate knowledge, understanding, and practical experience of the injection moulding process.


Demonstrate a thorough knowledge of the effect that material properties have on melt processing conditions.


Communicate effectively in written form.

Module Assessment Strategies

This module will be assesed by way of assignments, practical assessment and a final examination.

Indicative Syllabus


Overview of the principle of flow and viscosity by evaluating the effects of structure property relations under conditions of temperature and pressure.

Mixing and Compounding

Introduction to basic principles of mixing; choice and comparison of mixing and compounding systems for specific materials and applications


Basic screw types for single screw extruders, vented extruders. Overview of the main extrusion processes: tube, wire coating, sheet and film. Design of mixing heads for single screw extrusion. Coextrusion process. Comparison with twin screw extrusion. Introduction to screw and die characteristics. Fault diagnosis of common processing problems. Basic screw and die design considerations.

Injection Moulding

Construction of machines and types available: hydraulic, electric and hybrid systems. Multi-shot systems and micro machines. Types of mould locking systems and tie bar less machines. Screw designs. Moulding cycle. Overview of injection moulding non-standard materials such as elastomers and thermosets. The effects of moulding conditions and process variables on products e.g. shrinkage and orientation. Systematic approach to correction of moulding faults. The economics of injection moulding: The moulding cycle and the derivation of typical costings for moulded components. Heating and cooling requirements. Machine safety: requirements and types of safety mechanisms.

Blow Moulding

Principles of injection and extrusion blow moulding. Parison formation. Blowing systems. The effect of material properties on the product, also the effect of processing on the product.

Characterisation Techniques

Case studies on industry problems and how they were solved using thermal, mechanical and spectroscopy techniques.

Practical Content

Determination of the optimum moulding area diagram for a range of engineering materials.

Compounding polymer/nano clays composites with and without binding agents .

Effect of extrusion variables on the dimensions of an extruded profile.

Blending and injection moulding rubber/polymer compounds to enhance material properties.

Coursework & Assessment Breakdown

Coursework & Continuous Assessment
40 %
End of Semester / Year Formal Exam
60 %

Coursework Assessment

Title Type Form Percent Week Learning Outcomes Assessed
1 Written Report Continuous Assessment UNKNOWN 20 % OnGoing 1,2,3,4,5
2 Practical Evaluation - Practical/Oral Presentations Continuous Assessment UNKNOWN 20 % OnGoing 1,2,3,4,5

End of Semester / Year Assessment

Title Type Form Percent Week Learning Outcomes Assessed
1 Final Exam Final Exam UNKNOWN 60 % End of Term 1,2,3,4,5

Part Time Mode Workload

Type Location Description Hours Frequency Avg Workload
Lecture Distance Learning Suite Online lecture 1.5 Weekly 1.50
Independent Learning UNKNOWN Preparation for weekly class 1 Weekly 1.00
Independent Learning UNKNOWN Completion of weekly assignment / CA 1.5 Weekly 1.50
Independent Learning UNKNOWN Reading assignments 2 Weekly 2.00
Group Learning Not Specified Practical 8 Twice Per Semester 1.07
Total Part Time Average Weekly Learner Contact Time 2.57 Hours

Module Resources

Non ISBN Literary Resources

Principles of Polymer Engineering, N.G. McGrum, 1997

Principles of Polymer Engineering, Zehev Tadmor, Costas G. Gogos, 2006

The Physics of Polymers (3rd Ed), Gert Strobl, 2007

Polymer Melt Processing, Morton M. Denn, 2008

Polymer Extrusion, Polymer Processing Technology, Rauwendaal, Oxford University Press, 2001


Extrusion Processing Data, Alberto Naranjo C., Maria del Pilar Noriega E., Juan Diego Sierra M., Juan Rodrigo Sanz., Hanser, 2001


Materials and Processes in Manufacturing, E. Paul Degarmo, Wiley (9th Ed), 2003

Other Resources

Plastic and Rubber Weekly Journal

Newscientist Journal

Polymer Journal, Kunstoffe, Modern Plastics

Additional Information