Material and process for manufacturing plastic parts

A process for manufacturing plastic shells comprising the steps of providing a thermoplastic microspheres melt blended with pigment, said microspheres having an outside diameter in the range of 0.007″ to 0.040″;

• providing a mold and powder box;
• placing said microspheres into said powder box;
• joining the powder box to the mold;
• rotating the powder box to cover the mold with a charge of material that rests on the casting surface of the mold;
• melt flowing the material across the casting surface into a shape corresponding to the casting surface;
• removing excess material;
• and cooling and removing said shape from the mold.

A process for manufacturing plastic shells comprising the steps of providing an epoxy microsphere melt blended with pigment, said microspheres having an outside diameter in the range of 0.007 to 0.040″;

• providing a mold;
• placing said microspheres into a powder box, joining the powder box to the mold;
• rotating the powder box to cover the mold with a charge of material that rests on the casting surface of the mold;
• melt flowing the material across the casting surface into a shape corresponding to the casting surface, removing the excess material, and cooling and removing said shape from the mold.

A process for manufacturing plastic shells comprising the steps of providing thermoplastic microspheres melt blended with pigment, said microspheres having an outside diameter in the range of 0.007″ to 0.040″ and processing shells from such microspheres by slush molding said microspheres;

• said slush molding comprising the step of providing a mold and a powder box;
• placing said microspheres into said powder box;
• joining the powder box to the mold;
• rotating the powder box to cover the mold with a charge of material that rests on the casting surface of the mold cavity;
• melt flowing the material across the casting surface into a shape corresponding to the casting surface;
• removing excess material and cooling and removing said shape from the mold.

A process for manufacturing plastic shells comprising the steps of providing epoxy microspheres melt blended with pigment, said microspheres having an outside diameter in the range of 0.007″ to 0.040″ and processing shells from such microspheres by slush molding said microspheres, said slush molding comprising the step of providing a mold and a powder box;

• placing said microspheres into said powder box;
• joining the powder box to the mold;
• rotating the powder box to cover the mold with a charge of material that rests on the casting surface of the mold cavity;
• melt flowing the material across the casting surface into a shape corresponding to the casting surface;
• removing excess material and cooling and removing said shape from the mold.