Thermoset and thermoplastic materials are commonly used in the creation of various components, including knobs, handles, controls and more. While these two types of materials may seem similar, they differ in their chemical makeup and properties, which allows each to have unique advantages and disadvantages in how they are used.
What are the advantages of both Thermoset molding and Thermoplastic molding?
In terms of advantages, thermoset materials offer excellent stability and resistance to high temperatures, making it ideal for applications such as electrical components or industrial equipment that are subjected to harsher environments. This process also tends to be more cost-effective than other materials in high-volume production jobs, due to their ability to be molded quickly and with minimal waste.
Thermoplastic materials, on the other hand, offer greater flexibility and toughness, making them a popular choice for consumer products such as kitchen products or toys. They can also be easily recycled, reducing their environmental waste and increasing their appeal to environmentally conscious consumers.
Despite their differences, both thermoset and thermoplastic materials have their place in the creation of knobs, handles, and other components. By carefully considering the intended use and desired properties of the finished product, manufacturers can select the appropriate material and molding process to ensure a high-quality, durable product that meets the needs of their customers.
How does the process vary between Thermoset molding and Thermoplastic molding?
The process of creating knobs and handles from thermoset and thermoplastic materials can vary depending on the desired outcome, but there are some general steps that are common between both types.
First, the material is selected based upon the specifications of the final product.
- Thermoset materials, such as epoxy or polyester, are ideal for components that require high heat resistance and stability at different sizes.
- Thermoplastic materials, such as polypropylene or polycarbonate, are better suited for applications requiring flexibility and toughness.
After the material is chosen, it's usually melted or combined with other components to make it better. These can be things like coloring or materials that make it stronger. For thermoplastics, this process is relatively simple, as the material can be melted and molded repeatedly 
without significant changes in its properties. In contrast, thermoset undergoes a chemical change as it hardens. This means it is really important to mix the ingredients carefully and keep the temperature and time just right to make sure it turns out correctly.
After the material is prepared, it is molded into the desired shape using an injection molding machine. This involves heating the material to a high temperature and injecting it into a mold cavity under high pressure. The mold is designed to have the desired shape and features of the finished product, such as a textured grip or a threaded insert.
What are the options in finishing the molded product?
Once the material has cooled and become solid, the product is removed and finished. Finishing may involve:
- Trimming excess material
- Sanding rough edges
- Adding engravings or other markings
- Applying a coating or finish to improve the appearance or durability of the product
Creating knobs, handles, and other components from thermoset and thermoplastic materials is a relatively straight-forward process that requires expertise to execute properly at high volume. Attention to detail is crucial in order to achieve consistent quality and performance. When selecting the material and molding process, it's important to consider factors such as the component's intended use, expected lifespan, and any safety or regulatory requirements.
3-D printing prototypes are often very helpful when converting a metal part to plastic. Plastic parts are dent-resistant and lighter, and utilizing 3-D printing to prepare the prototypes allows the conversion process to move faster. Davies Molding has manufactured several metal to plastic conversion parts for the food service, commercial HVAC, and automotive industries. Details of these projects can be found in our 
Hydrographic printing is a popular trend for adding customizable designs, colors, and textures to shift knobs. As you might have guessed, it's a water-based printing process 
We have a long history of manufacturing plastic knobs, especially phenolic plastic knobs. But we also mold phenolic custom plastic parts, such as the plastic butterfly valve for the oil & gas industry. We started manufacturing butterfly valves a few years ago because the company that needed them got fed up with their overseas vendor. 
Are your metal parts rusting or denting? Do you need multiple operations such as welding and bending to machine your metal part? If you answered yes to either of those questions, you should consider switching to a plastic part. Plastic parts resist rust and denting, can be custom colored, and have high impact strength - not to mention are cheaper to produce. Want to learn more? We've put together a 24-page ebook to help you learn more converting metal to plastic parts and about the molding process-click 
