Thermoforming


Thermoforming describes the process of heating a thermoplastic sheet to its
softening point, stretching it over or into a single-sided mold, and holding it in place
while it cools and solidifies into the desired shape. The thermoplastic sheet is
clamped into a holding device and heated by an oven using either convection or
radiant heat until it is softened. The sheet is then held horizontally over a mold and
pressed into or stretched over the mold using vacuum pressure, air pressure, or
mechanical force. The softened sheet conforms to the shape of the mold and is held
in place until it cools. The excess material is then trimmed away and the formed
part is released. Excess material can be reground, mixed with unused plastic, and
reformed into thermoplastic sheets.

Thermoforming is commonly used for food packaging, but has many applications
from plastic toys to aircraft windscreens to cafeteria trays. Thin-gauge (less than
0.060 inches) sheets are mostly used for rigid or disposable packaging, while thick-
gauge (greater than 0.120 inches) sheets are typically used for cosmetic permanent
surfaces on automobiles, shower enclosures, and electronic equipment. A variety of
thermoplastic materials can be used in this process, including the following:

 Acrylic (PMMA)
 Acrylonitrile Butadiene Styrene (ABS)
 Cellulose Acetate
 Low Density Polyethylene (LDPE)
 High Density Polyethylene (HDPE)
 Polypropylene (PP)
 Polystyrene (PS)
 Polyvinyl Chloride (PVC)

As mentioned above, there are different methods of forcing the thermoplastic sheet
to conform to the mold. These types of thermoforming include the following:

 Vacuum forming - A vacuum is formed between the mold cavity and the
thermoplastic sheet. The vacuum pressure (typically 14 psi) forces the sheet to
conform to the mold and form the part shape.
 Vacuum Forming
 Pressure forming - In addition to utilizing a vacuum underneath the sheet, air
pressure (typically 50 psi, but up to 100 psi) is applied on the back side of the
sheet to help force it onto the mold. This additional force allows the forming of
thicker sheets and creating finer details, textures, undercuts, and sharp
corners.
 Pressure Forming
 Mechanical forming - The thermoplastic sheet is mechanically forced into or
around the mold by direct contact. Typically, a core plug will push the sheet into
the mold cavity and force it into the desired shape.

Mechanical Forming
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Capabilities
Typical Feasible
Shapes: Thin-walled:
Cylindrical
Thin-walled: Cubic
Thin-walled:
Complex
Part size: Area: 0.04 in² - 300 ft²
Materials: Thermoplastics
Surface finish - 60 - 120 μin 16 - 120 μin
Ra:
Tolerance: ± 0.04 in. ± 0.008 in.
Max wall 0.015 - 0.15 in. 0.002 - 0.25 in.
thickness:
Quantity: 10 - 1000 1 - 100000
Lead time: Days Days
Advantages: Can produce very large parts
High production rate
Low cost
Disadvantages: Limited shape complexity
Limited to thin walled parts
Scrap cannot be recycled
Trimming is required
Applications: Packaging, open containers, panels,
cups, signs

Understandi

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JISKI GAND MEIN JYADA DARD H VO YE B PADHE…….. OR
KRIPYA BTA B DE KIS KIS K DARD THA……..

……..SUCHNA JANHIT ME ZARI

 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
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 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.

 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. 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 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, 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.

 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 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 a mold. It then proceeds to another station
where formed parts are die-cut.