This spraying method for thermoplastic resins is a new manufacturing process for applying thermoplastics to a mold or surface in an efficient way that has the potential of reducing cycle time. Spraying thermoplastic resins is similar to spraying other polymers, such as paint, with the differences being higher pressure and temperature. This method uses an injection molding machine with a modified nozzle to spray the plastic material. In this study, temperature, pressure, and nozzle size were factors that influenced the success of this spraying method. The method of spraying in this study proved spraying without a gas is possible, a statistical analysis of a series of sprayed samples was performed, and a summary of the results is presented. This study is the only known method to use these procedures. The purpose of this thesis is two fold. First, its purpose is to achieve a method of spraying thermoplastic resins without the use of a combustible material. Second, if the spraying method is found to be possible, the thesis investigates what factors, of those selected; have a significant influence on the result? There are other types of spraying plastic methods used currently in industry. One such method, described in the project, is called Flame Spraying. This method, as well as others, has proven to be useful in protecting metals, wood, and other materials from harsh environmental and chemical elements. The results of this study proved that gasless spraying of thermoplastic resin is indeed possible and with further research this method can lead to a new manufacturing process for producing plastic parts or coatings. Future studies can include modifying factors such as temperature, plastic, pressure, tooling, and methods.



College and Department

Ira A. Fulton College of Engineering and Technology; Technology



Date Submitted


Document Type





thermoplastic, spraying, gasless



Technology Emphasis

Manufacturing Systems (MS)