Plasticforged

Plasticforged is a fabrication concept describing the deformation processing of thermoplastic polymers by applying heat and substantial mechanical pressure to produce a forged-like part. Unlike conventional molding, where the polymer is formed in a fixed cavity without significant plastic flow after solidification, plasticforging aims to realign polymer chains and reduce porosity through controlled flow in a die, yielding parts with improved density and mechanical properties.

Process: starting from billets or preforms, the material is heated to a forming temperature appropriate to the polymer (often above the softening point but below degradation). The heated billet is placed in a precision die and subjected to high-pressure compression or hammering using a press or hammer. The die shapes the final geometry. After forming, parts are cooled under controlled conditions to minimize residual stresses. Some processes allow multi-step forging or post-forming annealing.

Materials: engineering thermoplastics such as polycarbonate (PC), polyetheretherketone (PEEK), nylon, ABS, and reinforced variants are most commonly used. Thermosetting plastics and blends are less typical due to heat sensitivity.

Properties and considerations: potential benefits include higher density, improved yield and stiffness, better fatigue resistance, and near-net-shape parts that reduce machining. Challenges include tool wear, anisotropy from oriented chains, risk of warpage, moisture sensitivity in some polymers, and higher capital costs for forming equipment. Process parameters are material-specific and require careful control.

Applications and status: used in niche manufacturing for automotive components, electrical housings, and sporting goods where high strength-to-weight is valuable. It remains less common than traditional molding due to equipment cost and process complexity, with ongoing research to optimize material behavior and cycle times.