Module:7 Rapid Tooling 4 hours SLO: 17

Direct tooling & Indirect Tooling methods, Applications of Rapid Tooling in Reaction Injection
Molding, Wax Injection Molding, Vaccum Casting, RTV Silicone Rubber Molds, Spin-Casting, Cast
Resin Tooling, Hydroforming and Thermoforming.
5

Rapid tooling, sometimes known as prototype tooling or bridge tooling, is a fast and cost-efficient
way to carry out low-volume injection molding for a variety of types of plastic parts. Once the
aluminum or steel mold has been created with the rapid tooling process, it can be utilized as part of a
10 molding process to create multiple copies of a part. Rapid tooling is therefore used to create moldings
for rapid prototyping needs in a shortened timeframe, or to bridge the gap before high-volume
production.

Benefits of Rapid Tooling

15 Rapid production tooling gives a number of advantages over other mothods of prototype production:

Fast processing: Prototype tooling provides quick results, so the transition between development and
production is very short.
Customization: The rapid tooling process still allows for advanced customization of the mold.
20 Proof of concept/testing: Rapid prototyping facilitates practical real-world design testing and
troubleshooting solutions. It also enables quick and precise production of new tooling that
implements design changes and improvements.
Speed to market: Fast production and accurate tooling contribute to efficiency in production,
ultimately providing a faster introduction to the market than other methods.
25 Competitive pricing: The affordability of the rapid tooling process translates into a positive impact on
the bottom line for our customers.
1.Reaction Injection Molding
RIM(Reaction Injection Molding),is a Rapid Tooling process where parts are made from mixing and
injecting PU materials into a mold and cured through a process of polymerization (molecular cross-
30 linking)in a low pressure/room temperature environment.

RIM is a process in which two or more liquid intermediates (isocyanate and a polyol) are metered
separately to a mixing head where they are combined by high-pressure impingement mixing and
subsequently flow into a mold where they polymerize to form a molded part. Advantages that are
35 inherent in the process fall into three general categories: low pressure, low temperature, and use of
reactive liquid intermediate. RIM is also called reactive injection molding. If a plastic system of the
RIM type is sprayed against the surface of an open mold, the expression reactive spray molding
(RSM) is used.

With the pressures in the mixing head at between 1,500 to 3,000 psi (10.3 to 20.6 MPa), the in-mold
40 pressures are significantly lower than in many of the other molding processes. When comparing a
typical RIM in-mold pressure of 50 to 150 psi (0.4 to 1.1 MPa) with the 5000 to 30,000 psi (34.5 to
206.7 MPa) required for thermoplastic injection molding , it becomes apparent why RIM is
particularly suitable for larger parts. Automotive bumpers are routinely produced on RIM presses
 with 100 to 150 tons of clamping force, while comparable injection molded parts require presses of
3500 tons or more.

The temperatures used in RIM are also significantly lower. With polyurethanes (PURs), the
intermediates normally are processed at temperatures between 75 and 120F and the mold is usually
5 between 130 and 170F (266 to 338F). These lower temperatures obviously require significantly less
energy consumption than competitive processes.

The use of liquid intermediates has additional benefits beyond the low pressures and temperatures
involved. A tremendous amount of design flexibility is possible with RIM. Since the mold is filled
with low viscosity liquid, very complex part configurations can be produced. Ribs, mounting bosses,
10 slots, and cut out areas are all possible. RIM parts are being molded with wall sections as thin as
0.100 in. and as thick as 1.5 in. Also, moldings can incorporate variations in thickness within the
same part. Incorporation of inserts for mounting or reinforcement is also practical. Since the mold is
filled before polymerization occurs, there are no molded-in stresses to cause part warping or cracking
after demold.

15 The relative case of compounding thermoset and thermoplastic liquid formulation allows a great deal
of flexibility in fine tuning the material to the requirements of the part. By changing variables such as
filter type and level, blowing agent concentration, pigment, and catalyst the properties of the plastic
can be optimized for the specific application.

The two major classifications for RIM products are (1) high-density, high-modulus, flexible
20 elastomers and (2) low-density structural foams. Automotive trim and fascia are usually elastomers.
Furniture and equipment housings are frequently molded as structural foams (especially when texture
and/or sound deadening are included in the product specifications).

About 85wt% of the processed PUR are elastomeric. The rest is rigid, usually structural foam that has
a solid skin encasing a foamed core. PURs can be used with physical blowing agents such as
25 halocarbons. Foaming is an integral part of the RIM process even for solid products because it
compensates for the shrinkage that occurs during polymerization. That is why most elastomeric
products also include foaming agents. This same approach is used during injection molding solid
plastics; where up to 5wt% of a blowing agent is used to compensate for shrinkage.

Overall RIM has advantages over the standard low-pressure mechanical-mixing systems in that larger
30 parts are possible, mold cycles are shorter, there is no need for mold solvent-cleaning cycles, surface
finishes are improved, and rapid injection into the mold is possible. Large and thick parts can be
molded using fast cycles with relatively low-cost materials. If surface coating is required the types
used are coating paint, in-mold coating, film, and metallic facings. Its low energy requirements with
relatively low investment costs make RIM attractive. Applications are many; they include automobile
35 bumpers, medical products, radio and TV cabinets, furniture, sporting equipment, appliances, and
business-machine housings.

40
 https://www.youtube.com/watch?v=TWEfbGH-Ewc

2. Wax Injection Molding

5

In addition to two-part resin molding, silicone cavities also are suitable for low-pressure injection
molding of waxes for investment casting.

Using a low pressure, injection system, semi-molten wax is forced into the silicone cavity until full.
10 The cavity is then chilled until the wax has fully solidified. The wax is then removed from the cavity
and the process repeated. However, due to the fragility of the investment casting wax material,
extreme care must be exercised when removing wax parts from the silicone tool.

3. Vaccum Casting
15

Vacuum Casting is a copying technique used for the production of small series of functional plastic parts. Using
two-component polyurethanes and silicone molds, Vacuum Casting is known for its fast production of high-
quality prototypes or end-use products.

20 Ideal applications for Vacuum Casting

 Pre-launch product testing

 Small series of housings and covers
 Concept models and prototypes

1. What Is Vacuum Casting?

25 This is a casting process for elastomers which uses a vacuum to draw any liquid material into the mold. Vacuum
casting is used when air entrapment is a problem with the mold.

Additionally, the process can be used when there are intricate details and undercuts on the mold. Also, it is applied if
the material used to make the mold is fiber or a reinforced wire.

The process is sometimes called thermoforming because the manufacturing process involves rapid prototyping
30 where the plastic sheets are preheated. The materials are preheated in an automated vacuum casting machine until
they are soft and pliable.

2. How Does Vacuum Casting Work?

Vacuum casting follows a process which is used to make the final product.

• Have A High-Quality Master Model

 Vacuum casting process requires you to have a high-quality master model. The high-quality master model can be the
industrial part itself. Additionally, you can use a model created using stereolithography, which is a case for the
prototyping applications.

You should always ensure that the master model being used is of the correct dimensions and looks. This is to ensure
5 that no flaws are transferred to the model prototype after finishing the process.

• Cure Process

The master model is then encapsulated into a two-part silicone rubber mold. The mold is cured under high
temperatures to ensure that the two parts stick together. This is used to strengthen the mold and make it more
durable.

10 After the mold is cured, it is cut open to reveal a hollow space at the center, which has the exact dimensions of the
master model. After the mold is cut into two, it is placed in the vacuum chamber. Then, later on, the mold is filled
with the designated material to make a product.

• Filling The Resin

You should fill the mold with the designated material. The resin replicates the characteristics of industrial material.
15 The resin material is usually mixed with metallic powder or any coloring pigment to achieve aesthetic or specific
functional properties.

After the mold is filled with the resin material, it is placed in the vacuum chamber. It is placed in the vacuum
chamber to ensure that there are no air bubbles in the mold. This is to ensure that the final product is not ruined or
damaged.

20 • Final Cured Process

The resin is placed in the oven for the final cured stage. The mold is cured in high temperatures to ensure that the
material is strong and durable. The silicone mold is removed from the mold so that it can be used in making more
prototypes.

After the prototype is removed from the mold, it is painted and decorated. The painting and designs are used to
25 ensure that the product has a gorgeous final look.

3. Benefits Of Vacuum Casting

The following are advantages of using vacuum casting on duplicating products.

• High Precision And Fine Detail To The Finished Product

When you are using silicone as the mold to your products. It ensures that the final product has great attention to the
30 details. The final product ends up looking like the original product.

Every attention to detail is considered and taken into account. Even when the original product has the most complex
geometry, the final product looks like the original.

• High Quality Of The Product

 The products made using the vacuum casting method are of high quality. Also, the use of resin allows you to choose
the right material to be used in making of the final product.

This allows you to have a wider choice of flexibility, hardness and rigidity you want in your products. Also, this has
a great influence on the final appearance of the product since the material used plays a major role.

5 • Lowers The Production Costs

Using the vacuum casting process to make the product is more economical. This is because the process uses silicon
to make the molds. Silicone is affordable as compared to aluminum or steel and makes great final products.

Moreover, the material allows you to make more products from the mold. This makes this process more cost
effective as compared to the use of 3D printing.

10 • A Great Method When You Want To Meet A Deadline

This method is fast, and it takes you less time to finish making the finish products. You can take seven to ten days to
make around 50 functioning prototype parts.

This method is amazing when you are making a lot of products. Additionally, it is great when you are working
towards meeting a deadline.

15
https://www.youtube.com/watch?v=zlBM3zAl5gY

https://www.youtube.com/watch?v=sHqHWTK-Esg

20
4. RTV Silicone Rubber Molds

Room Temperature Vulcanization (RTV) rubber molds are the least expensive and fastest way to create about a
dozen prototype parts. As shown in the figure below, even with undercuts, the part is able to be removed through
25 distortion of the mold. The figure illustrates a small toy locomotive molded with urethane.
 Urethane casting material is commonly used for product prototypes. Urethane can be formulated to have material
properties similar to elastomers or ABS. Urethane can be machined, sanded, glued, and painted. Urethane can have
material properties, color, and surface texture very similar to that of production materials.
 

5 An RP pattern is used to create a master male pattern as shown below. The RP technique most often used is the SLA
process.

The SLA part is made slightly larger (e.g. 0.003 in/in) than the final product since this is what shrinkage the final
part will see.

The SLA part is sanded to a suitable cosmetic finish and can be sealed.

10 The master pattern is fitted with a sprue and gate and then surrounded by a parting surface which establishes the
parting line for the mold (see the illustration). Alternatively, the cured mold can be cut carefully to form the parting
line.

The assembly is fixtured in a vat, and liquid RTV is then poured over the pattern and parting surface combination as
15 shown below.
 Once cured, the RTV is removed from the vat and separated from the pattern and parting line surface to yield the
two halves of the molding tool. RTV air-cures, so that the cure time depends on the geometry, the RTV type, and the
environment. Cure time can range from .5 to 40 hours. Aging of the mold after cure for up to three days can
5 improve mold life.

Thermoset resin such as urethane is poured or injected into the mold, as shown below.

Finally, the finished part is removed from the mold. Undercuts are overcome by distorting the mold, which springs
back to its original shape as long as distortion is not too severe.The part must then be post-processed by trimming
10 any flash, as shown below, and possibly sanding. The gate and sprue must also be removed.

https://www.youtube.com/watch?v=NlzAuOncN2k
 5. Spin-Casting,

Spin casting, also known as centrifugal rubber mold casting (CRMC), is a method of utilizing inertia to produce
castings from a rubber mold. Typically, a disc-shaped mold is spun along its central axis at a set speed. The casting
5 material, usually molten metal or liquid thermoset plastic, is then poured in through an opening at the top-center of
the mold. The filled mold then continues to spin as the metal (or thermoset plastic) solidifies.

Silicone molds

The spin casting process typically uses vulcanized silicone or organic rubber as the mold-making substrate.
Vulcanization is an integral step that occurs halfway through the mold-making process. Prior to vulcanization, the
10 mold rubber is a soft and malleable solid-like fluid, in many ways very similar to Silly Putty. Because of the clay-
like nature at this stage, the mold is easily cut or shaped to accommodate irregular models. Vulcanization serves two
purposes: establishing the negative space inside the mold as well as hardening the rubber so it will remain strong
and rigid during casting.

After vulcanization, before it is usable, the mold must undergo gating and venting. This involves carving channels
15 to ensure proper air and material flow during the casting process. Gating and venting is typically done by hand
using a sharp knife or scalpel and varies in time depending upon the complexity of the mold. The final product is a
cured rubber mold which can withstand anywhere from hundreds to over a thousand casting cycles before
replacement is needed.

Casting materials

20 Metal

Generally, the casting materials used for competing processes like metal die casting and injection molding are
similar, but not suitable for spin casting. For example, a typical zinc die-casting alloy such as Zamak 3 can be used
but will solidify too rapidly from a molten state when cast with centrifugal force. This typically results in
incomplete filling of the mold as well as a rough, porous finish, called orange peel. Zamak 2, of a slightly different
25 composition, was originally developed as a gravity-cast alloy with greater finished strength but was found to work
well with spin-casting. Its extra copper content encourages the eutectic behaviour and gives a lower freezing point.
It has become known as 'Kirksite' and has given rise to a range of dedicated spin-casting alloys, some with
additional components, such as magnesium, to control the surface finish.

To ensure replicable casting cycles of accurate reproductions with a high quality finish, the spin casting process
30 requires casting materials with the following qualities, for the following reasons:

Low temperature operation - Spin casting is a low temperature process, as overexposure to high temperatures causes
the rubber mold to degrade. Depending on the actual compound, the mold may become overly soft or hard while
forming cracks and chips.

Slow solidification and low viscosity - Uniform and unrestricted flow of the casting material has a substantial effect
35 on the quality and finish of the final items.

Plastic

Aside from the aforementioned metal alloys, thermoset resins and plastics work well with spin casting as they can
be introduced as liquids and will set or solidify while the mold spins. In general, spin casting encourages the use of
 casting materials that are liquid upon introduction to the mold and solidify at a slow, uniform rate during the spin
cycle.

Equipment

5 A 24" front-loading spin caster

Spin caster

During the casting process, the finished mold spins along its central axis for anywhere from 30 seconds to several
minutes depending upon the chosen casting material. Internally a spin casting machine or spin caster consists of a
motor and pressure clamping system which holds and positions the mold properly while it spins at a steady rate.
10 These components are placed inside of a machine body which shields against flashing of molten metal or liquid
plastic that is inadvertently ejected from the mold during the spinning process. Without the proper containment, hot
melted flashing can be a serious hazard to nearby persons.

Commercial spin casting machines are available in two different types, front-loading and top-loading. Owing to the
weight and bulkiness of spin casting molds, front loading machines tend to offer several advantages regarding ease
15 of use and time savings. Rubber molds can become quite heavy, especially at larger diameters and when casting
metal. Because loading and unloading the caster is performed by hand, it is easiest and less fatiguing to manipulate
the mold at waist level in one fluid motion as allowed by a front-loading spin caster. This is important in production
spin casting, to maximize the number of casting cycles per hour.

Top loading machines tend to be cheaper and theoretically have less of a restriction on maximum mold thickness.

20 Vulcanizer
 12" and 18" vulcanizing presses

Vulcanization is a necessary step to prepare the uncured silicone mold for spin casting. Under controlled heat and
pressure the silicone slowly cures to a heat-resistant, flexible, permanent mold. The vulcanizing press or vulcanizer
5 uniformly compresses the mold while exposing it to heat for several hours. The vulcanizer consists of a pair of
parallel heated platens mounted on a hydraulic press. Smaller or home-made vulcanizers may compress the mold
via screws or a heavy duty clamp instead of hydraulic pressure. Some spin casting operations choose to forgo
running their own vulcanizer and procure molds from a supplier.

Melting furnace

10

An electric melting furnace

A melting furnace is necessary only when spin casting metal. The metal must be molten prior to introduction into
the mold. It is necessary for a spin casting furnace to have a temperature controller, as there is an optimal range for
each metal. For example, a particular zinc alloy is typically cast between 775 and 800 °F, whereas it actually melts
15 much lower around 500 °F. If the metal is introduced to the mold at a higher temperature (in this case, above 800
 °F), it will wear the silicone prematurely, shortening the mold life. If the metal is introduced at significantly lower
temperatures (below 775 °F), its solidification time will similarly be shortened resulting in incomplete or low
quality castings. Spin casting metal requires a furnace with fine temperature control, and knowledge of proper
casting temperature.

5 https://www.youtube.com/watch?v=cQ-NUrqdyY4

10 6. Cast Resin Tooling

This is one of the simplest and most economical methods of producing a tool for the  injection molding of
thermoplastic parts.

It consists of mounting a pattern within a mold box, setting up a parting line, and then painting and later pouring
15 resin over the pattern until there is sufficient material to form one half of the tool. After completing the first half, the
process is repeated for the other half of the tool. There are many tooling resins available with different mechanical
and thermal characteristics – with epoxy being one of the most popular. The resins are often loaded with aluminum
powder or pellets to improve the thermal conductivity and compression strength of the tool and to reduce the cost of
the resin. Cast resin tools are usually used for 100 to 200 molded parts, although it’s possible to get up to 1,000 parts
20 – depending on the material being molded.

The advantages of this process are that it’s fast, relatively simple, and can be used to mold common thermoplastics
such as polypropylene and ABS. A disadvantage is the low mechanical strength of the molds, especially when the
mold includes small thin features. For this reason, this method of rapid tooling is only suitable for relatively simple
shapes. Also, the low thermal conductivity of the mold material lengthens the molding cycles times.

25 https://www.youtube.com/watch?v=MdMMxG_0UXQ
https://www.youtube.com/watch?v=5DXBYb8If4w

7. Hydroforming

30 Hydroforming basically is a technique that uses a fluid either to form or aid in forming a part from ductile metal.
Figure 1shows a part that was hydroformed from sheet metal.
 The most common type of hydroforming used, tube hydroforming changes the cross-sectional shape of a tube from
the normal round to other shapes that change along the part's length (Figure 2). Hydroforming creates a much more
precisely and intricately formed tube than was possible 20 years ago. Although tube hydroforming is relatively new
5 in its scope of applications, using fluid to form metal dates back more than 100 years, when the process was
patented for forming boiler components and musical instruments. A common application for several decades has
been making copper plumbing T's (Figure 3). Even though using fluid to form metal has a long history,
developments in the last 15 years matter most to potential hydroformers today.

10

Approximately 15 years ago, tube hydroforming was used to produce large structural parts with higher load-bearing
characteristics and to improve rigidity. Up to that point these needs had been addressed largely by stamping parts
and fabricating them into an assembly that was structurally tubelike. This method offered a high degree of design
15 flexibility with respect to generating the desired shape. It also allowed accurate hole placement and relatively
complex part geometry.

The stamping and fabricating method reduced rigidity at the welded joints, which inherently are more flexible. Also,
welding created distortion, which caused a lot of dimensional variation. Although the costs associated with stamping
20 and fabricating parts might have appeared high, this process was the best option at the time.
 Hydroforming changed the rules of forming structural parts by making it possible to form a tubelike structure from
a tube rather than stamping and fabricating it from sheet metal. The concept of starting with a straight round tube,
bending it, and then forming it to change its cross-sectional shape continuously along its length generated a number
of advantages and changed several aspects of design flexibility.

5 Tube Hydroforming Benefits

In structural design, it is widely accepted that tubes support loads more strongly and efficiently than stamped sheet
metal, even when the latter is welded together into a tubelike assembly. Concurrently engineers and designers are
learning how and where best to apply tube hydroforming, and new capabilities are being developed continually. As
design options increase and improve, hydroforming is being used to produce more and more parts. Benefits
10 associated with using this technology also are increasing.

Hydroforming reduces weight; part, tool, and capital costs; dimensional variability; the number of parts; and the
number of joints. It also increases or improves structural strength; bending and torsional rigidity; other performance
characteristics; certain aspects of design flexibility; and overall part quality.

Some Hydroforming History

15 The story of how tube hydroforming came to be used as it is today for large structural parts has at least two
beginnings. First, the process most commonly used today is based on the one used for making copper plumbing T's,
which starts with a straight tube, uses high internal fluid pressure to expand and directly form the part, and then
pushes more material into the end to compensate for wall stretching. Less than 15 years ago, this process was
adapted to make even larger structural parts. Distinguishing features of this process are:

20 Die is closed before introducing fluid

Fluid is the primary forming medium

Cross section expands

Relatively high pressure (usually greater than 20,000 PSI)

The second beginning was a separate development 15 to 20 years ago motivated by the need to address product
25 design and forming limitations and dimensional instability. A process (Process A, Figure 4) was developed
specifically for larger structural parts and was the real beginning of using hydroforming for this purpose. In this
process, the tube is filled with low-pressure fluid (one-third to one-fifth the pressure used for the earlier plumbing T
process) before the die is fully closed. Water acts as an aid to prevent collapse while the forming die closes, where
the die is the primary former. Normal design practice uses a constant periphery along the part while the shape
30 changes. (The final forming pressure, while higher than when the die is closing, is one-third to one-fifth the pressure
used for the earlier T process.) The final part's periphery essentially equals that of the start tube.
 Common Process Steps

Tube hydroforming normally begins with a straight round tube. Other shapes can be used, but round provides the
greatest number of part design options. Preforming commonly includes bending to make the tube follow the general
5 layout of the desired final part. Also required in many cases is cross-sectional performing.

Hydroforming is next, often coupled with in-die hole punching. This usually is followed by removing end scrap and
welding additional components to the newly formed tube.

Some part designs and process requirements make it necessary to use special material, tube quality standards,
lubrication (and cleaning), additional hole cutting outside the hydroforming die, and other processes. These factors
10 will add cost, which can be worth it for the "value" they provide. However, they should be implemented only after
considering alternate design approaches and processes that may render these steps unnecessary.

Tube Hydroforming Applications

Most high-profile tube hydroforming applications have been concentrated in the automotive industry, primarily
because the perception was and strongly remains that the benefits are most valuable on vehicle structures.
15 Essentially, tube hydroforming can be used for any structural application in any industry. The main condition that
needs to be met is that changing from one method to tube hydroforming provides enough benefits to be worthwhile.

Hydroforming animation:
https://www.youtube.com/watch?v=1QPSCXEoJKQ
20 Hydroforming of Chasis
https://www.youtube.com/watch?v=fOkCKOWpUr0

25

8. Thermoforming.
 Thermoforming is a plastic fabricating process which involves heating sheet plastic and forming it over a male or
female mold. The two basic types of thermoforming processes - vacuum forming and pressure forming - and
derivative processes, such as twin sheet thermoforming, make plastic thermoforming a broad and diverse plastic
5 forming process. Thermoformed plastics are ideally suited for automotive, consumer products, packaging, retail and
display, sports and leisure, electronics, and industrial applications.

The most advantageous aspects of thermoforming are its low tooling and engineering costs and fast turnaround time
which makes thermoforming or vacuuforming ideal for prototype development and low-volume production.

Advantages of the Thermoforming Plastic Sheet Process

10  Extremely adaptive to customer design needs

 Rapid prototyping development
 Material and process is optimized for cost effectiveness
 High-speed production allows for just-in-time shipments
 Flexible tooling design offers a competitive advantage
15  On-the-fly product enhancements with low additional costs
 Visually pleasing appearance
 Weight savings for consumer and manufacturer
 Wider design scope
 Lower tooling costs
20  No anticorrosion spray necessary
 Paintable and colored plastic availability
 Fully integrated process with limitless flexibility
for small to large product designs

Understanding the Different Types of Thermoforming

25 Vacuum Forming

Vacuum forming is a plastic thermoforming process involving forming thermoplastic sheets into three-
dimensional shapes through the application of heat and pressure. In lay terms, vacuum forming refers to all
sheet forming methods, including drape forming, which is one of the most popular. Basically during
vacuum forming processes, plastic material is heated until it becomes pliable, and then it is placed over a
30 mold and drawn in by a vacuum until it takes on the desired shape.

Pressure Forming

This process is similar to vacuum forming, except with the addition of pressure, which pushes the sheet into
the shape of the mold. This process is mainly used for parts requiring styling and aesthetic qualities because
pressure forming creates greater detail, allowing for textured surfaces, undercuts and sharp corners, which
35 are not as easily created with vacuum forming.

Twin Sheet Forming

 Twin-sheet thermoforming is a process of vacuum or pressure forming two sheets of plastic essentially
simultaneously, with a separate mold on the top and bottom platens. Once the plastic has been molded, it
remains in the molds, and while still at its forming temperature the two molds are brought together under
high pressures, and the two sheets are welded wherever the molds dictate a weld.

5 Plug Assist

Plug assist forming is a widely used forming technique and requires the use of a female (cavity) mold. The
limited depth of draw of female molds is improved by the use of plug assist.

Vacuum Snapback

Vacuum snap back is an often used process for forming deep draw products with a uniform wall thickness.
10 Vacuum is used to pre-stretch the hot plastic before the mold makes contact with the sheet. Vacuum snap-
back, while more complex than plug assist, can produce deeper drawn products with better wall uniformity
and less mark-off when completed.

Billow Forming

A method of thermoforming sheet plastic where the heated sheet is clamped over a billow chamber. Air
15 pressure in the chamber is increased causing the sheet to billow upward against a descending male mold.

Free Forming

This method of thermoforming does not use a mold. Instead, an acrylic sheet is clamped in a frame and
either a vacuum or compressed air draws the material to a desired depth. An electric eye determines when
the proper depth has been reached and cuts off the pressure. Since only air touches the sheet of material,
20 there is no markoff.

Drape Forming

In drape forming, a sheet of plastic is heated and stretched down, generally over a male mold. Next,
depending on the shape of the mold, gravity alone will pull the material to the mold or commonly, a
vacuum is applied to draw the sheet to the mold which will more detail to the inside of the part.

25 Stretch Forming

A plastic sheet forming technique in which the heated thermoplastic sheet is stretched over a mold and
subsequently cooled. It is quick, efficient, and has a high degree of repeatability.

Matched Die Forming

In this process, both halves of the part are formed by molds with no vacuum or air pressure. The sheet is
30 heated until it is soft, and then both mold halves clamp together to form the part. Used with parts that do
not have large draws.

Inline Thermoforming

In this process the plastic film moves from a roll onto the inline equipment and through the heating section.
The heated material advances into the forming section where pressure and/or vacuum force the plastic onto
35 a mold. It then proceeds to another station where formed parts are die-cut.
 https://www.techniform-plastics.com/youtube-gallery-01.html
https://www.techniform-plastics.com/product-gallery-01.html

https://www.youtube.com/watch?v=LYfzl8eciG8
5