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Topics covered:
Both
the videos and the Companion Volume discuss Basic Thermoforming
Methods, Costing, Mold and Product Design, Assembling the Appropriate
Team, Plastic Materials, Production of Film and Sheet by Extrusion,
The Heating of Film and Sheet, Heating System Requirements, Tooling
(molds, plug assists, and trim tooling), Vacuum and Compressed Air
Systems, Safety, The Plant Environment, Effective Problem Solving,
and Troubleshooting.
Who will
benefit from this series:
The
two 45-minute videos and the Companion Volume were written for thermoforming's
decision makers: supervisors, technicians, managers, process engineers,
mold and product designers, cost estimators, maintenance staff,
and quality personnel. The Safety, Effective Problem Solving, and
Troubleshooting would be particularly
valuable
in the training of operators.
Materials and
machinery suppliers who sell, or want to sell, into the thermoforming
market, will also find value in the series as an information tool
for customers.
Customers who
buy and use thermoformed products will gain a greater understanding
of what it takes to design, quote, and make the products. Both the
thermoformer and customer will enjoy the benefits of clear, more
effective communication.
Product designers
who must compare and choose among competing processes: thermoforming,
injection molding, hand lay-up, and sheet molding compound will
learn something of value.
TABLE OF
CONTENTS
BASIC THERMOFORMING
METHODS
¨
Vacuum Forming
¨ Pressure Forming (Use of Compressed Air)
¨ Mechanical Forming
¨ Modifications of Basic Forming Methods
¨ Webbing Prevention
¨ Prestretching
¨ Snap Back
¨ Bill Snap Back
¨ Plug Assist
¨ Billow Plug Assist
¨ Twin Sheet Thermoforming
This chapter explores the most well-known processes and their
advantages or disadvantages as they relate to tooling, forming,
ancillary equipment and machinery. Schematics, line diagrams and
photos are used to illustrate parts, processes and molds.
COSTING
¨
Economics and Costing in the Design Stage
¨ What Must Be Considered When Estimating Cost
¨ Elements of Production Costs
¨ Sheet Weight Formulas
Costing can
make the difference between profit and loss, yet it is easy to
overlook vital details. Comprehensive checklists are included
in this chapter to assist in establishing material, tooling and
processing costs.
MOLD AND
PRODUCT DESIGN
¨
Design Guide Outline
¨ Establishing Guidelines
¨ Preliminary Design Considerations
¨ Detail Part Design
¨ Following Through
¨ Design Details
Guidelines
and checklists are presented, to help ensure that the appropriate
steps are taken during the design cycle.
INVOLVING THE APPROPRIATE TEAM
¨
Team Players
¨ Suppliers
Producing
a successful product involves cooperation from internal and external
sources.
PLASTIC MATERIALS
¨
Thermosets
¨ Thermoplastics
A synopsis
of the two major classes of polymeric materials, and how they
relate to the thermoforming process. Tables are provided for Key
Material Properties and Standard ASTM Terminology for Abbreviated
Terms.
PRODUCTION
OF FILM AND SHEET BY EXTRUSION
¨
The Extrusion Process
¨ Feedstocks
¨ Orientation
¨ Regrind
¨ Sheet & Film Spec Checklist
An overview
of the extrusion process is the essential first step in the manufacture
of thermoformed products. Understanding how film and sheet are
made is an indispensable tool for establishing a repeatable process
and building a good relationship with your supplier.
HEATING REQUIREMENTS
¨
Thermoforming Processing Temperatures
¨ Heat Transfer Modes
¨ Principles of Radiant Heating
Sheet temperature
and forming rate are crucial elements in thermoforming a quality
part. This chapter explores how plastics are heated and how forming
temperature affects both the material and the finished part.
TOOLING
¨
Molds-Design & Construction
¨ Plug Assists
¨ Cooling Fixtures
¨ Trimming Fixtures
¨ Tooling Spec Checklist
¨ Mold Design & Ordering Spec Checklist
Well designed
and well built tooling is important to achieving consistent, economical
thermoformed parts. Diagrams, checklists and tables are provided
to help the thermoformer to make sound, informed decisions about
tooling.
VACUUM AND
COMPRESSED AIR
¨
Vacuum Systems
¨ Basic Vacuum Pressure Measurements
¨ Determining Vacuum System Capacity
Rapid, controlled
forming is the key to consistent thermoformed parts, and vacuum
and compressed air systems must be properly designed, built, and
maintained. This chapter outlines the principles.
GOOD THERMOFORMING PRACTICES
¨ Safety
in the Plant
¨ The Plant Environment
¨ Record-keeping
¨ Developing a Repeatable Process
¨ Process Monitoring
¨ Effective Problem Solving & Troubleshooting
¨ Sheet Extrusion Troubleshooting Guide
This final
chapter discusses general rules of safety, the effects of ambient
conditions on employees, materials, and the process; good record-keeping,
achieving a repeatable process, monitoring the process, and logical
problem solving. An extensive Troubleshooting table covers everything
from blisters to tearing.
WILLIAM K. "BILL" MCCONNELL, JR.
- Author
Bill is president of McConnell Co., Inc., Ft. Worth, TX, which provides
comprehensive consulting work to the Thermoforming Industry. He's
also called upon to be an expert witness for thermoforming-related
legal issues.
Honors
and Achievements:
¨ The
1st Thermoformer of the Year
¨ Lifetime Achievement Award
¨ Fellow of SPE
¨ Plastics Pioneers Association
¨ Founding Member of the SPE Thermoforming Division
¨ SPE Thermoforming Division Board Member
¨ International Seminar and Workshop Instructor
¨ Published Author
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