Thermoforming

Product Design and Manufacturing

Minicurriculum
Dr. Seth Bates
Spring, 2005
Thermoforming
Tech 140 Polymers and Composites
2
Thermoforming and Other Molding Processes
While extrusion and injection molding processes are by far
the most common types of methods used for molding
polymers, other molding methods can offer better
economic, quality and production advantages depending on
the application
In many cases (such as for very large items like pressure
tanks, furniture and appliance casings) injection nor
extrusion processes can feasibly handle the job
However, extrusion or injection molding may provide a preform
shape that other methods then form
Thermoforming of polymer sheet uses extruded, skived or
molded sheet stock
Thermoplastic welding uses rod stock that has been extruded
Spring, 2005
Thermoforming
Tech 140 Polymers and Composites
3
Thermoforming
There are many variation of thermoforming, but the process essentially
involves molding a heated sheet of thermoplastic into or over a mold
face using vacuum, air pressure, matched molds or a combination
thereof
In order to be thermoformed, the sheet material should be able to
withstand its own weight at the process temperature, otherwise there
may be excessive sagging,(or support systems must be installed)
As in most processes there are pros and cons at various processing
temperatures; low temperatures allow the sheet to support itself but reduce
the ability of the material to contour over the mold
Higher temperatures help the material to flow over the mold and reduce
polymer chain orientation, but can cause excessive sag, degradation or
wall thinning
Most thermoplastics can be thermoformed, however some can not
because of viscosity problems (too low or too high) at the processing
temperature
Spring, 2005
Thermoforming
Tech 140 Polymers and Composites
4
Vacuum Thermoforming
Lab 9 in the lab guide demonstrates this method; one of the simplest
and one of the least expensive methods of thermoforming
The process involves placing a heated sheet of thermoplastic over a
male or female mold and sealing it to the mold flange; vacuum isthen
drawn between the sheet and the mold which causes atmospheric
pressure to push down the plastic sheet and conform to the mold
contours
The mold has strategically placed vacuum holes or slits to ensure air will
not be trapped between the mold and sheet
Because the sheet must be held in place by some kind of retaining
device (like a frame or clamp) there is most often scrap generated from
trimming the part; this material is recycled
Thinning of vacuum formed parts at corners and deep draws shouldbe
kept in mind since these places will be weaker than the walls;
Spring, 2005
Thermoforming
Tech 140 Polymers and Composites
5
Schematic of Vacuum Forming Set-Up
Spring, 2005
Thermoforming
Tech 140 Polymers and Composites
6
Drape Forming
Drape forming is very useful for producing deep draw
parts
In drape forming, the hot sheet is mechanically stretched
over the mold and sealed around the base of the mold; a
vacuum is then drawn between the mold and the plastic
sheet
As with all thermoforming, the best detail is obtained on
the part side in contact with the mold
The thickest sheet section is at the top of the mold where
the sheet initially makes contact
The thinnest section is where the mold side wall and base
join
Spring, 2005
Thermoforming
Tech 140 Polymers and Composites
7
Plug Assist Forming
There are several variations of plug assist forming, whichever is
used, plug assist forming alleviates many of the problems
associated with straight vacuum and drape forming by pre-
stretching the sheet to be formed before contacting the mold
Wall thickness on the parts can be controlled better
Polymer chain orientation can be lessened
The process works by forcing a plug, about 80% of mold cavity
volume, to prestretchthe hot sheet being formed while
simultaneously pressurizing or pulling vacuum
Doing this evenly increases the surface area of the sheet beforemolding
and allows more material to be draw into corners and deep recesses where
the sheet would normally be excessively stretched by straight vacuum
forming
Spring, 2005
Thermoforming
Tech 140 Polymers and Composites
8
Different Variations of Plug Assist Forming
Pressure bubble plug assist
Plug assist pressure forming
Plug assist vacuum forming
Spring, 2005
Thermoforming
Tech 140 Polymers and Composites
9
Plug Assist Air Slip Forming
Spring, 2005
Thermoforming
Tech 140 Polymers and Composites
10
Matched Mold Forming
Matched mold thermoforming relies on
mechanical force to form the hot sheet between a
male and female die whose profile match up
The best advantage this method has it producing
parts with highly reproducible quality and
tolerance
Fine detail can also be achieved with this method
One half of the mold is typically covered or coated
with an elastomericmaterial to make alignment
less critical when matching up the mold halves
Spring, 2005
Thermoforming
Tech 140 Polymers and Composites
11
Free Forming & Mechanical Forming
Lab 8 in the lab guide demonstrates fee air
forming; here a closed mold or a template may be
used
Skylights, and aircraft canopies are good examples of
free air blow forming
Lab 10 demonstrates aspects of mechanical
forming
Mechanical forming simply involves using forming jigs
and templates to shape sheet, rod or other polymer
basic shape
Forming is accomplished by heating the polymer
preform and then forcing it around the contour of the
jig or template