Direct Compression Moulding (DCM)
The Orthoplastics insert compression moulding process
High standards and expectations at Orthoplastics demand that all customers are provided with premium quality products. Therefore, Orthoplastics use a process called Direct Compression Moulding to sinter polymers. This method of moulding polymers results in an outstanding high gloss finish, thereby resulting in a near net shape, or net shape component.
Extra attention has been paid to advancing this method, allowing Orthoplastics to use the optimum approaches towards producing the best possible UHMWPE components for their clients. Orthoplastics successfully developed an ‘insert moulding’ process which enables them to mould UHMWPE onto or into another titanium, steel or ceramic part.
Direct Compression Moulding Services
Orthoplastics’ Direct Compression Moulding services are at the cutting edge of new product development. Although the technology has been in existence since the 1990’s, the new generation of technologies which have been invested in, particularly the 3D printer, allows printed metals and other porous metals technologies to be created.
This has provided Orthoplastics with the ability and opportunity to over-mould plastics, and create a mono-block solution for customers and device manufacturers.
DCM allows medical grade moulding of individual components
Although Direct Compression Moulding is a premium method of sintering the polymer - compared to traditional consolidation methods - it has the capability to produce products which cannot currently be produced, pushing the design envelope for medical grade orthopaedic components.
By focusing on innovation, this method of manufacture has produced unique over moulding capabilities. Producing Mono block components that have a high gloss moulded surface. These design and aesthetically pleasing products provide an alternative market solution to any OEM’s portfolio.
Each component is individually moulded, allowing the finite controlling of all aspects of pressure, temperature and time, during critical consolidation. The finished product’s high gloss surface finish and tolerances are superior when compared to a machined UHMWPE component.
What is Direct Compression Moulding (DCM)?
Direct Compression Moulding, often referred to as DCM or insert compression moulding, is a high-precision process used to form solid polymer components through controlled compression and sintering, typically without the use of solvents or melt flow. This technique compacts polymer powder under high pressure and temperature to create dense, near-net-shape parts with excellent surface finish and mechanical integrity.
At Orthoplastics, we specialise in DCM for UHMWPE and related advanced polymers. Our process is engineered to deliver high gloss, tight tolerances, and the flexibility to mould polymers directly onto or into substrates (e.g. titanium, steel, ceramics) to create monolithic or overmoulded hybrid assemblies.
Frequently Asked Questions
We’ve answered some of the most common queries about our materials including performance, processing, applications and more.
When is compression moulding the preferred manufacturing method?
Compression moulding is typically preferred when producing high-quality polymer components with consistent material properties. It is well suited to applications where material integrity and uniformity are critical.
What are the advantages of compression moulding for polymer processing?
Compression moulding enables efficient material usage and helps produce components with reliable structural performance. It is often used where consistency and repeatability are important in manufacturing.
How does compression moulding support material performance?
By applying controlled heat and pressure, compression moulding helps ensure even material distribution. This supports consistent mechanical properties throughout the finished component.
What types of components can be produced using compression moulding?
Compression moulding is commonly used to produce solid shapes and near-net components that can be further machined into finished parts. It is suitable for applications requiring precision and durability.
What should be considered when choosing compression moulding?
Key considerations include component size, material selection, production volume and required tolerances. Evaluating these factors helps determine whether compression moulding is the most effective manufacturing approach.
