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What Does An Injection Molded Part or Product Look Like?


Precision and strength are just two reasons why injection-molded products are one of the fastest growing segments of the plastics industry. They come in countless shapes, sizes and colors!

But what does an Injection Molded Part or Product look like?



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How Are Lotion Pumps Made?


Plastic lotion pumps, one of the most popular dispensing methods for viscous (thick liquid) products in the personal care and beauty industry, come in all shapes and sizes. Many of these parts are Plastic Injection Molded!  When used as designed, pumps dispense the right amount of product time after time. But have you ever wondered what goes in a lotion pump to makes it work? While there are hundreds of different designs in the market today, the basic principle is the same.  Here is an overview of these components, and how they contribute to the overall functionality of pumping the product from the bottle to your hand.

Generally speaking, a lotion pump consists of the following components :


ActuatorAn actuator, or the pump head, is what the consumer presses down to pump the product out of the container. The actuator is often made of Polypropylene plastic and can have many different designs – and often come with a up-lock or down-lock features to prevent accidental output,. This is one of the component designs that can set one pump apart from another when it comes to the exterior design, it is also the part where ergonomics play a role in consumer satisfaction.

The component that screws the entire assembly onto the neck finish of the bottle. It is identified with the common neck finish destination such as 28-410, 33-400. Often made of Polypropylene plastic, it is often designed with a rib side or smooth side surface. In certain cases a shiny metal over-shell can be installed to give the lotion pump a high-end, elegant look.

Outer GasketThe gasket is often friction fitted to the inside of the closure and it acts as a gasket barrier on the bottle land area to prevent product leakage. This outer gasket can be made from a wide variety of materials depending on the manufacturer’s design : Rubber, LDPE are just two of the many possible options.

HousingSometimes referred to the pump assembly housing, this component holds all the pump components in place as well as acting as a transfer chamber that sends the product from the dip tube to the actuator, and ultimately to the user’s hand. This component is often made of Polypropylene plastic. Depending on the lotion pump output and design, the size of this housing can differ greatly. 

Stem / Piston / Spring / Ball (Interior components inside the housing)These are the parts that can vary based on the design of the lotion pump. Some may even have additional components that aid the product flow, and some designs may even have additional housing components that isolate the metal spring from the product pathway, these pumps are generally referred to have a “metal free pathway” feature, where the product will not come in contact with the metal spring – eliminating the potential compatibility problems with the metal spring.

Dip TubeA long plastic tube made of Polypropylene plastic that extends the reach of the lotion pump to the bottom of the bottle. Depending on the bottle the pump is paired with, the dip tube length will differ.  A properly cut dip tube will maximize product usage and prevent clogging.

How Does it Actually Work?

A lotion pump acts much like a air suction device that draws the product from the bottle to the consumer’s hand despite the law of gravity telling it do the opposite. When the consumer presses down on the actuator, the piston moves to compress the spring and the upward air pressure draws the ball upwards, along with the product inside, into the dip tube and subsequently the chamber.

As the user releases the actuator, the spring returns the piston and actuator into it’s up position, and the ball is returned to it’s resting position, sealing the chamber and preventing the liquid product from flowing back down into the bottle. This initial cycle is called “priming”. When the user presses down on the actuator again, the product that is already in the chamber will be drawn from the chamber, through the stem and actuator, and dispense out of the pump and onto the consumer’s hand. If the pump has a bigger chamber (common for high output pumps), it may require additional priming before the product will be dispensed through the actuator.

Lotion Pump Output

The output of a plastic lotion pump is often measured in cc (or ml). Commonly in the range of 0.5 to 4cc, with some larger pumps with bigger chambers and longer piston / spring components having output up to 8cc. Many manufacturers have multiple output options for each of their lotion pump offerings, giving the product marketer full control of dosage.

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85 Historical Dates Told By Mr. Spock That You Should Know About Right Now Which Caused Major Changes For The Plastics Industry


Mr. Spock will walk us through 721 years of “Fascinating” developments and commercial applications which have led to increasingly rapid changes in the plastics industry from 1284 to 2005.

In fact many ancient peoples worldwide used naturally occurring plastics for a range of decorative and functional purposes. 

These included materials such as bitumen, amber, waxes, lac and rubbers and especially horns of different types were molded or shaped, some being filled and used as coatings.

1284   The Horners Company was recorded and it was awarded a Royal Charter in 1638.  By 1725 London was a major center for molding of horn.

1850s  Shellac compounded with wood flour was patented in the USA (S. Peck,  J. Critchlow) and molded into union cases, picture frames, etc.

1855   Bois durci was patented by Francois Lepage, being hard dark moldings of albumen or blood with wood flour capable of durable fine replication under  heat and pressure.

1880   Phonograph records (Berliner) based on shellac compounds were introduced and continued until PVC was used in the 1950s.

1897   Casein plastics derived from milk patented by Adolph Spitteler (Bavaria).    This important material was developed by Erinoid (1909) for a range of pastel and colored items.

1656    John Tredescant introduced gutta percha from the Far Eastern Palaquium ree bark. This produced a hard material moldable by heat to soften and rovide products which proved to have unique properties.

1843    Dr William Montgomerie introduced GP to the Royal Society of Arts and illustrated its molding properties.  Excellent electrical and chemical resistances underpinned technical progress, whilst imitation wood mouldings provided artistic outlets.  Montgomerie used GP for handles and golf balls which, in 1846, revolutionized the game.

1845    Gutta Percha Co. (C. Hancock, H. Bewley) was founded in London and developed an extrusion process for rods and tubing.  Bewley, 1845-50, designed the first extruder for applying GP and rubber insulation to copper cables used in submarine telegraph links.  The company became The Telegraph Construction and Maintenance Co. Ltd. (Telcon) which continued manufacturing submarine cable for over a century.

1846     R. and J. Dick Ltd., founded in Glasgow, are still making belting from GP.

1849     The first temporary dental filling compound employed GP.

1851     The Great Exhibition featured over 100 applications of GP.

1730   Charles Marie de la Condamine reported long established rubber uses in the Amazonian basin, e.g. bottles.  Imports to Europe developed from his work with Francois Fresneau.

1770   Joseph Priestly (of oxygen fame) gave rubber its name because of its ability to rub out charcoal marks on paper (India Rubber).

182043 Thomas Hancock investigated intensively the molding of masticated rubber and its many uses.

1839   Charles Goodyear (USA) revealed vulcanization of rubber with sulphur, allowing formulation variables to provide a wide range of resilience in moldings.

1843   Hancock refined and patented vulcanization, establishing the UK rubber industry with products including boats, springs, hoses and bands. Vulcanite (hard rubber or ebonite) was an important innovation.

1846   Charles Macintosh bought Alexander Parkes’ ‘cold cure’ vulcanization process which allowed production of brightly colored fabrics using organic dyes.

1851   Nelson Goodyear (USA) patented ebonite primary thermosetting material for demanding applications, e.g. battery boxes, pumps, telephones, dental plates and fountain pens.

1861   Francis Shaw introduced the first screw extruder for rubber production.

1920   Peter Schidrowitz prepared prevulcanized latex, leading to the ‘dipped rubber goods’ industry.

184668 Alexander Parkes followed Schonbein’s earlier work with detailed studies of nitro-cellulose as a thermoplastic base material.  A great stride forward was made with Parkesine molded from doughs to resemble ivory or horn. New products in controlled volume outputs became possible.  Over 20 patents were filed. Parkesine was introduced at the 1862 London Exhibition.

1869-70 John Wesley Hyatt (USA) patented Celluloid – a camphor modified cellulose nitrate – a readily moldable material for billiard balls, spectacle frames, photographic film, etc.

1877-84 Extensive legal actions between Hyatt and Spill established Parkes as the true inventor of camphor modified cellulose nitrate.  In 1878 J. W. Hyatt was granted US Patent 202441 for injection molding thermoplastics.

1880     Cellulose nitrate combs began to be mass produced by BXL which by the 1890s caused a decline in the crafting of tortoiseshell and horn products. By 1920 celluloid replaced such combs and its use continued until the 1950s.

1887    The Revd. Hannibal Goodwin patented celluloid film for photographic and  other uses.

1892    Cross, Bevan and Beadle patented cellulose acetate regenerated from chemically treated wood pulp for fibers and threads. This was followed by Cross and Bevan producing tough, fire resistant thermoplastic products many colours for applications spanning some 50 years.

1905    J. Edwin Brandenberger (USA) invented cellophane used in thin films for fabrics and packaging providing major applications for many years.

1900     J.  Kondakov (Ger.) synthesized methyl rubber poly (dimethylbutadiene).

1910     S. V. Lebedev (USSR) produced (BR) rubber from poly (1, 3 butadiene).

1915     Synthetic methyl rubber production began in Leverkusen.

1930     E. Tschunker developed nitrile rubbers (BUNA) produced in 1939 in the USA.

1931     W. Carothers et al (Du Pont USA) produced polychloroprene rubber (Neoprene).

1937     O. Bayer (Ger.) developed urethane rubbers introduced in the same year by R. M. Thomas ((USA).

1939-40  Waldo Semon (Goodrich) developed viable polybutadiene and styrene-butadiene rubbers which made major contributions to World War II.

1943     Silicone polymers were introduced by Dow Corning Corporation following much earlier work by Frederick Kipping on organo-silicon compounds.

1899     Arthur Smith patented phenol-formaldehyde resins to replace ebonite for electrical insulation.

1904     The Fireproof Celluloid Syndicate (later became the Damask Lacquer Co. Ltd. – Sir James Swinburne) developed phenol-formaldehyde lacquers for metal.

1907      Leo Baekeland (USA) formed phenol-formaldehyde resins (p/f) and produced over 100 patents.

1909      Leo Baekeland patents Bakelite, the first major thermoset material to replace wood, ivory, ebonite, etc.

1910      Formica electrical insulation laminate was produced by H. Faber and D O’Conor (USA) using p/f resin impregnated paper plies.

1912      I. Ostromislensky (Russ.) patented the polymerisation of vinyl chloride to give unstable PVC polymer (unstable when not modified).

1913      Klatte produced polyvinyl acetate.

1918      Hans Johns patented urea-formaldehyde resins.

1922      Herman Staudinger (Ger.) proposed long chain molecular structures for polymers and synthesized rubber.

1924-28 Edmund Rossiter developed water-white transparent moldings from thiourea-formaldehyde resins (marketed as Beetle resins from 1928).

1926      The first truly successful commercial injection molding machine was produced in 1926 by Eckert and Ziegler (German Patent 495362).

1927      Otto Rohm (Ger.) developed poly (methyl methacrylate) clear plastic.

1927-37 Wallace Carothers headed major Du Pont team into ‘designed’ macromolecules, e.g. Neoprene rubber introduced in 1931 followed in 1934 with Nylon fiber (Nylon 66; Hill).

1931      Heidrich (Germany) produced the first screw extruder specifically for thermoplastic processing.

1938      Nylon 6 fiber (Schlack, I. G. Farben) commercially produced as Perlon.

1932      J. Crawford, R. Hill, ICI, introduced PMMA – Perspex, followed by others.

1933-40 Henkel patented melamine production for melamine formaldehyde resins.  Developed by Ciba, American Cyanamid as basis for molding powders (Melaware) and M-F surfaced laminates (Formica).

1933     W. Semon produced stable PVC polymer (Goodrich).

1933     R. Whiley (Dow) discovered polyvinylidene chloride (Saran).

1933     First injection molded polystyrene articles produced following earlier work  by BASF and Dow Chemicals (produced in scale in 1937).

1933      Fawcett and R. O. Gibson (ICI) discovered low density polythene, full commercial production in 1939.

1933     Carlton Ellis patented unsaturated polyester resins, introduced commercially into the USA 1941.  (Cold-cured styrenated polyesters introduced in 1946 for fibre reinforced plastics.)

1937     Hans Kellerer (Austria) introduced a fully automatic injection molding machine capable of continuous operation.  R. Colombo and C. Pasquetti (Italy) produced the first twin screw extrusion machines.

1938      R. Plunkett (Du Pont) discovered PTFE.

1939      Bayer, I. G. Farben introduced polyurethane systems.

1939     Castan in Ciba (Swiss) produced foundation epoxy resins.  1945 Ciba produced epoxy resins following pre-cursor work by Schlack (Ger.)  using bisphenol A/glycidyl ethers.

1940    Du Pont introduced Polyacrylonitrile  (PAN) polymer, an early engineering product.

1940    PET – poly(ethylene-terephthalate) synthesized by J. R. Whitfield and J. T. Dickson at Calico Printers Association.  ICI Terylene fibres and Melinex films followed (also Dacron and Mylar from Du Pont).  In 1977 oriented blow molded drinks containers were launched based on PET polymers and other types, e.g. PBT – poly(butyl-terephthalate).

1947     Formica melamine faced decorative p/f laminates were introduced to the UK.

1953    Karl Ziegler with E. Holzkamp produced high molecular weight, low pressure poly(ethylene) using organo-metallic catalysts; a major step forward.

1953    Drs H. Schnell (Bayer) and D. Fox (General Electric) independently produced polycarbonate pioneering engineering polymer.  Industrial production after 1958 provided the basis of optical discs and high impact resistant applications.

1954    Isotactic polypropylene discovered by Guilo Natta, Montecatini, using Ziegler type catalysts.  ICI produced ‘Propathene’ used in high volumes for demanding domestic and engineering applications.

1955     Du Pont patented EVA (ethylene-vinyl acetate copolymer) with the Elvax range launched in 1960.  This is a versatile range of products.

1959     Du Pont launched Delrin – polyformaldehyde polymer based on work under Robert McDonald since 1947.  This proved to be a valuable light engineering polymer.

1961-62 Du Pont introduced polyimide films (Kapton) and varnishes and later foams for composite structures.  The resins are capable of high insulation, fire resistant and mechanical properties.

1964    Polyphenylene oxide (PPO) polymers were patented by General Electric (USA) and introduced as the Noryl range in 1966.  These were widely used as high performance engineering thermoplastics.

1965    Union Carbide, 3M and ICI produced polysulphone thermoplastic engineering polymer.

1965    PEEK – Poly(ether.ether ketone) resistant chemical and engineering polymer produced by ICI.

1966    Fekete et al synthesized vinyl ester polymers (bisphenol A/acrylic variants). Produced by Dow Chemical Co. as the Derakane series.

1961   The First Century of Plastics – Celluloid and its Sequel;  Morris Kaufman; (Fundamental landmark publication.)

1962   Paint Technology Manuals series – Oil and Color Chemists Association; Chapman and Halley

1974   The Technology of Adhesives;  Delmonte;  Reinhold Publishing Corp., (Wide ranging details of many thermoplastic/thermosetting polymers.)

1980   Developments in Reinforced Plastics;  ed. G. Pritchard;  Applied Science Publishers, 1980.  (Reviews of many resin/reinforcement systems.)

1981   Fibre Composite Hybrid Materials;  ed. N. L. Hancox;  Applied Science Publishers, 1981.  (High performance polymers, adhesives and reinforcements etailed for design and moulding of composites for demanding applications, e.g. prosthetics.)

1994   Early Plastics;  Sylvia Katz;  Shire Publications Ltd., (Illustrated guide to plastics and design.)

1997   Early Plastics – Perspectives 1850-1950, ed. Susan Mossman, Leicester University Press 1997.

1999  ‘Plastics-  The Layman’s Guide’ by James Maxwell, IOM Communications Ltd., 1999.

2005   Tears of the Tree;  John Loadman;  Oxford University Press, (Definitive rubber history and technology.)