Systems and methods for reprocessing polymeric material during a molding process

A method for reprocessing resin during a molding process, the method comprising:

• disposing a polymer material into a hopper of a molding system, the hopper being coupled to a barrel having a screw disposed therein;
• feeding the polymer material through an input of the barrel and into the barrel;
• heating the barrel;
• rotating the screw, wherein rotating the screw presses the polymer material against an inner wall of the barrel to create shear forces sufficient to alter the molecular structure of the polymer material and form a compounded material;
• and
• advancing the compounded material through an output of the barrel and into a mold.

A modified injection molding system with direct line compounding, the comprising:

• a barrel for feeding a polymer material to a mold, the barrel defining an area;
• a hopper for supplying the polymer material to the barrel;
• a screw disposed in the barrel, the non-reciprocating screw having an outer diameter that is within 0.125 inches or less of an inner diameter of the barrel such that the barrel fills 90% or more of the area of the barrel;
• wherein the screw is configured to rotate within the barrel;
• wherein the barrel defines an enlarged output configured to enhance the flow of material from the barrel to a mold, the enlarged output having a diameter of 0.1875-2.0 inches or more and that is larger than the outer diameter of the screw;
• and
• wherein feeding the polymer material along the screw and through the barrel imparts shear forces onto the polymer material sufficient to alter the molecular structure of the polymer material and form a compounded material.