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    14 Thermoforming

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    suhas deshpande
    Thermoforming is a manufacturing process that uses heat and pressure to form thermoplastic sheets into complex shapes. There are several variations of thermoforming including vacuum forming, pressure forming, plug assist forming, and reverse draw forming. Key equipment used includes thermoforming machines, molds made of various materials, and trimming equipment. Process considerations include the material properties, part design factors like draw ratio and area ratio, and plant operations like material and part handling.

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    14 Thermoforming

    Uploaded by

    suhas deshpande
    845 views27 pages
    Thermoforming is a manufacturing process that uses heat and pressure to form thermoplastic sheets into complex shapes. There are several variations of thermoforming including vacuum forming, pressure forming, plug assist forming, and reverse draw forming. Key equipment used includes thermoforming machines, molds made of various materials, and trimming equipment. Process considerations include the material properties, part design factors like draw ratio and area ratio, and plant operations like material and part handling.

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    14 thermoforming

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    Thermoforming is a manufacturing process that uses heat and pressure to form thermoplastic sheets into complex shapes. There are several variations of thermoforming including vacuum forming, pressure forming, plug assist forming, and reverse draw forming. Key equipment used includes thermoforming machines, molds made of various materials, and trimming equipment. Process considerations include the material properties, part design factors like draw ratio and area ratio, and plant operations like material and part handling.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    845 views27 pages

    14 Thermoforming

    Uploaded by

    suhas deshpande
    Thermoforming is a manufacturing process that uses heat and pressure to form thermoplastic sheets into complex shapes. There are several variations of thermoforming including vacuum forming, pressure forming, plug assist forming, and reverse draw forming. Key equipment used includes thermoforming machines, molds made of various materials, and trimming equipment. Process considerations include the material properties, part design factors like draw ratio and area ratio, and plant operations like material and part handling.

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    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    of 27

    Thermoforming

    MFG 355
    Thermoforming Variations
    • Vacuum
    • Pressure
    • Plug assist
    • Reverse draw
    • Free
    • Drape
    • Snap-back
    • Matched die
    • Mechanical
    Vacuum Forming
    • Vacuum draws the part against the mold
    “cavity”
    Pressure Forming
    • Air pressure presses the sheet against the
    mold “cavity”
    Plug Assist Forming
    • Plug stretches the material for a more
    evenly distributed part
    Reverse Draw Forming
    • Vacuum stretches material before forming
    for a more uniform part
    Free Forming
    • Parts are blown
    • No contact with mold surfaces
    • Excellent optical clarity
    Drape Forming
    • Mold “cavity”
    protrudes upward
    Snap-Back Forming
    • Two stage
    vacuum forming
    process
    • Stage one pre-
    stretches
    material
    • Stage two forms
    the material on
    the mold
    Matched Die Forming
    • Upper and lower mold “cavities” mate up
    or match
    • For greater detail
    • For complexity
    • High tolerances
    Mechanical Forming
    • No positive or negative air pressure
    applied to mole
    • All molding is done by mechanical means
    • There is less detail than most of the other
    processes
    • Can also be a matched die process
    Blister Pack and Skin Pack
    • Blister pack has space between material
    and packaged part
    – Usually a moderately rigid material
    – A mold is still needed
    • Skin pack sheet is held firmly against part

    – Flexible materials are used


    – No mold is needed
    Blister Pack and Skin Pack

    Blister Packs

    Formed blister pack material

    Skin Packs
    Twin Sheet Thermoforming
    • Thermoforming of two sheets
    simultaneously
    • Multiple colors or textures
    Equipment
    • Machines
    Equipment
    • Machines
    Equipment
    • Machines
    Equipment
    Skin Pack Machine
    • Machines
    Shuttle Mold Machine

    Vacuum Former

    Blister Pack Machine


    Equipment
    • Molds
    – Materials
    • Wood
    – 50-100 parts
    • Fiberglass
    Wooden mold
    – Up to 50,000 parts
    (treated for
    • Metal longer life)
    – Millions of parts

    Fiberglass mold
    Metal Mold
    Equipment
    • Molds
    Equipment
    • Trimming
    – Robotic trimming
    – Die cutting
    Equipment
    • Plant Considerations
    – Material handling
    • Sheets
    • Rolls
    – Part handling
    • Secondary processes
    • Trimming
    – Scrap handling
    • Regrind/disposal
    Product Considerations
    • Materials
    – Thermal profile
    • Thermoforming does not take the material to Tm
    • Material must have a Tg
    • Thermal degradation is possible
    – Extruded or cast sheet
    – Specialty Handling
    • Drying, pre-conditioning
    Product Considerations
    • Shapes and Part Design
    – Undercuts
    • Core pulls
    – Size
    • Depth, surface area
    Product Considerations
    • Draw Ratio (depth to width)
    – Normally should not exceed 2:1 but can go to
    7:1
    • Area Ratio (area before forming to area
    after forming)
    – Measures the amount of thinning, for
    instance, 1:2 means that the material is half
    as thick (assuming uniform thinning)
    Operation and Control
    • Speed of vacuum application
    • Temperature of the mold
    • Size of the bubble
    • Plug size
    Thank You

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