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High temperature moulding: PPS versus PEEK, the 200 °C mould requirement, machine and tooling specification, crystallinity, annealing and supplier qualification.
PBT and PET moulding: grade families, drying limits, thin-wall flow length, fibre-driven warpage, flame ratings by wall thickness, hydrolysis and connector selection.
Acetal moulding: the 220 °C ceiling and why it matters, homopolymer versus copolymer, mould temperature and crystallinity, stainless tooling and machinability.
Polyamide moulding: the two opposite moisture targets, drying schedules, conditioning methods, the moisture gradient in thick walls, glass fibre trade-offs and under-bonnet grades.
Polypropylene moulding: why shrinkage varies from 1.2 to 2.6 %, how to control warpage, how a living hinge actually works, and the automotive and closure requirements.
Polycarbonate moulding: why 0.02 % moisture is the limit, the processing window, residual stress tests, flow length limits, optical part requirements and medical qualification.
ABS moulding in practice: the nine grade families, the processing window, design rules, finishing routes including plating, regrind limits and the defects specific to ABS.
The full cost of profile extrusion tooling: die cost drivers, indicative prices, the hidden items, amortisation per metre, die life and maintenance, and what to ask a toolmaker.
Quality control on a profile line: the process parameters worth logging, product measurements, SPC subgroup design, in-line instruments, records and complaint handling.
Extrusion tolerances by standard and material, how to read a profile drawing, the secondary operations menu with achievable tolerances, and a worked cost comparison per part.
Why extruded profiles bow and twist: the four causes, how to specify straightness properly, residual stress tests, mechanical straightening and what tolerance is actually achievable.
Wood plastic composite extrusion in practice: formulation and coupling agents, moisture and drying, machine configuration, die and calibration, surface finishing and WPC defects.
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