Thermoforming

Product Design and Manufacturing Minicurriculum Dr. Seth Bates

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
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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

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Thermoforming Tech 140 Polymers and Composites

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 is then 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 should be kept in mind since these places will be weaker than the walls;

Spring, 2005

Thermoforming Tech 140 Polymers and Composites

Schematic of Vacuum Forming Set-Up

Spring, 2005

Thermoforming Tech 140 Polymers and Composites

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
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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 prestretching 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 prestretch the hot sheet being formed while simultaneously pressurizing or pulling vacuum
Doing this evenly increases the surface area of the sheet before molding and allows more material to be draw into corners and deep recesses where the sheet would normally be excessively stretched by straight vacuum forming

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Thermoforming Tech 140 Polymers and Composites

Different Variations of Plug Assist Forming

Plug assist vacuum forming Pressure bubble plug assist

Plug assist pressure forming

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Plug Assist Air Slip Forming

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Thermoforming Tech 140 Polymers and Composites

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 elastomeric material to make alignment less critical when matching up the mold halves
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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
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