|
|
SPE
Industrial Thermoforming Symposium & Workshop
For
Thin & Heavy Gage Thermoforming
Sponsored
by the Thermoforming Division of the
Society of Plastics Engineers
March 1 – 5, 2004
Held at
the
Crowne Plaza, 7050 Stemmons Freeway, Dallas Market Center, Dallas,
TX 45247
Phone: (214)630-8500
|
Workshop
Outline Workshop Fees General
Information Registration
WORKSHOP
LEADER: William "Bill" McConnell - Biography
WORKSHOP
OUTLINE
Sunday
night, February 29, 2004
Welcome Reception: 6:00 to 8:00PM
Funded by Our Sponsors
-Plenty to eat and drink!
-Great networking atmosphere!
-Come and introduce yourself to the other participants, speakers and sponsors
in this informal setting
Monday,
March 1st 8:30AM to 5:00PM
Introduction to Thermoforming
Bill McConnell
8:30 to 9:00AM
definition-history-future
the ten fundamentals
of thermoforming
Thermoforming Optically
Clear Parts
Guest Speaker-Jim Irion
9:00 to 10:15AM
Texstar, Inc.
material types
processes
secondary treatments
inspection methods
Coffee Break
Vacuum Requirements &
Materials for Thermoforming
Bill McConnell
10:30 to 12 noon
vacuum requirements
materials for thermoforming
production of sheet
& film
Lunch 12:00 to 1:00PM
Thermoforming Methods
Guest Speaker-Arthur Buckel
1:00 to 5:00PM
vacuum
pressure
mechanical
pre-draw stretching
plug assists
combination forming
slip forming
twin sheet forming
Welcome Reception
6:00 PM-8:00 PM
Funded by Our Sponsors
Great Networking Atmosphere!
Come and introduce yourself to the other participants, speakers and
sponsors in this informal setting.
Plenty of food and drink!
Tuesday,
March 2nd 8: 30AM-5:30 PM
Measurements Methods in
Thermoforming
Dennis C. Northrop,
Technical Service Manager
8:30 to 9:35AM
Avery Dennison, Performance
Films Division
Useful and innovative ideas
to reduce thermoformed part variation, control process variation, and
improve customer satisfaction
Understanding
Variation
o Special Cause
o Common Cause
Measurement Methodology
o Precision
o Resolution
o Repeatability
Measurements
used to Produce Extruded Sheets and Coils.
o Polymer Properties
o Gauge Control
o Aesthetics
§ Color
§ Surface Imperfections
Measurements
used During the Thermoforming Process
o Location
o Measuring Sheet Temperature
o Timing
o Measurements During Forming
§ Vacuum
§ Pressure
§ Cooling
§ De-molding
o Identifying Critical Parameters
Measuring Thermoformed
Parts
o Understanding Shrinkage
o Elongation
o Dimensional
o Critical Characteristics
Putting It Together
for Your Customer!
o Set-up Sheets
o Understanding Capability
o Specifications
Plant Tours
Leave for Skyline
Tour @ 9:50 AM
1.Tour: Skyline CareerDevelopment Center
- City
high school career development plastic shop
Lunch 11:45
AM-12:30 PM
Leave for Spartech
Tour @ 12:45 PM
2. Tour: Spartech Plastics
- Custom sheet extrusion
plant
3. Tour: Better
Bath Components
-
Large Custom Thermoforming Plant
Return to
Hotel by 6 PM
6:30 PM bus leaves For
Trail Dust Steakhouse
FUNDED BY OUR SPONSORS
7:00PM to 9:00PM
Requirements: dress in your best “cowduds”
Wednesday, March 3rd 9:00AM-5:15PM
Heating
Bill McConnell
9:00 TO 10:15AM
convection
conduction
radiation
-radiation theory
-types of radiant heaters
-checking oven for heat uniformity
Coffee Break
Tooling
Bill McConnell
10:30AM to noon
male vs. female
construction
vacuum holes, slots
break-aways and
undercuts
temperature control
mechanical helpers
Lunch 12:00 - 1 PM
Troubleshooting
Bill McConnell
1:00-2:15PM
pilot error
mechanical
material
heating
pressure (vacuum & compressed air)
controls
Trimming
Robert Browning
2:15-3:15PM
routing and drilling
sawing
punching, shearing,
and compression
robotics
high-pressure waterjet
and laser
Coffee Break
Plastics Testing
And Quality
Control for the Thermoformer
Guest Speaker-Don Hylton
3:15 - 5:15PM
Technical Service
and Consulting
Clark Atlanta University polymer chemistry
molecular structure
morphology
introduction to rheology
key material characteristics in the thermoforming process
process accountability principle
what does the process look like
heat histories
sources of heat histories
plastics testing for thermoforming
ASTM (American Society for Testing and Materials)
quality assurance/quality control
specifications for incoming raw materials and process
control
Thursday, March
4th 8:30AM-5:00PM
Changes In Design
and
Mold Manufacturing
Guest Speaker-Ken Griep
8:30-9:15AM
Portage Casting & Mold, Inc.
an initial request
for quote
quotation
design and prototype
part
production
Rigidizing
Bill McConnell
9:20 10:15AM
bonded doublers
fiberglass spray-ups
twin sheet
foam-in-place
Coffee Break
Forming with
Style
Project Management From the Designer to Out the Door
Guest Speaker – Richard Freeman
Freetech Plastics
10:30AM to NOON
The practices, equipment, and tooling needed
Thermoforming with style
So you want to be a thermoformer?
Where is our industry today?
How to use quality improvement to expand markets
CNC machining and trimming equipment may be the best
investment you can make
Basics of 3 and 5 axis CNC equipment
Advantages and disadvantages of each
What you need to know before you buy
How to check equipment to keep it performing right
The basics of plastics machining
Basic programming principle
Why are some CNC machine controllers smarter than others
Trimming, fixturing and fabricating tips
Lunch
Roll-Fed Tooling
Guest Speaker-Barry Shepherd
1:00PM to 5:00PM
Roll-Fed Machines Basic vacuum former with
guillotine cut-off
In-line pressure former with trim and stack
Contact heat cut-in-place
In-line with free-standing trim press
Tooling Design
Considerations for Roll-Fed Machines
Customer Wish List
Run Quantity
Cavity Spacing
Trim Press Tonnage
Form/Trim Registration
Material
Form Press
Platens
Stand-offs
Mold Bases
Molds: Male/Female
Assists: Plug/Perimeter
Clamping: Pinch
Bar/Perimeter/Cavity
Temperature Control
Air Pressure
BREAK
Trim Press
Dies: Steel Rule/Forged/Matched
Metal
Cutting Anvils
Cutting Plates
Heated Dies/Plates
Die Sets: Locators/Floating
Dies
Challenging Trim
Applications
Stacker
Magazines
Pushers/Strippers
Off-Load Devices
Friday, March 5th 8:00AM-1:00PM
Thermoforming Design for Designers of Thin and Heavy Gage Products
Guest Speaker–Robert Browning
McConnell Co., Inc.
8:00 AM - 1:00 PM
Concentration on thin and
heavy gage pressure and twin sheet forming, tooling and design. An in-depth
comparison of pressure and twin sheet forming with vacuum forming and
other competitive molding processes, such as injection molding, structural
foam, blow molding, rotational molding and fiberglass.
The program is especially
appropriate for plastic parts designers, thermoforming personnel, quality
control, sales engineers, purchasing, tooling personnel, equipment manufacturers
and sales personnel and resin and sheet producers. Slides, videos and
sample parts will be incorporated into the presentation.
Introduction
Process review
Single-sided vacuum forming
Materials and properties
Thermoset vs. thermoplastic
Molding and trimming
Tooling Design and Considerations
Undercuts
Male and female mold
Molds for thin gage
Articulating molds
Plug assist
Tooling checklist review
Prototypes and samples
Creative Design Alternatives Thermoforming
Pressure forming – thin and heavy gauge
Twin sheet forming
Mechanical Considerations How is a part
used?
Effects of friction and wear
Ribs and gussets
Tolerances
Material thinning and control
Molded inserts and hardware
Environmental Considerations
Operating
environment
Exposure to sunlight and weather
Appearances, Finishes
and Decorating Style
Shape
Color
Texturing
Surface finish
Molded-in details, names, logos
Design Limitations in
Thermoforming Do’s
and don’ts in design
When to look at other processes
Product Development Management
From design concept
to troubleshooting
ADJOURN –
1:00 PM
A
Special Thanks to Our Sponsors
Aristech Acrylics (Robert Tieman)
Avery Dennison (Dennis Northrop)
Brown Machine (Jim Robbins)
Chevron Phillips Chemical Company (Clark Meese)
Emerson & Cuming Composite Materials Inc. (Paul DiNicola)
Empire Plastics (Vincent McElhone)
Kleerdex Company (John Rogan)
Land Instruments (William "Bud" Foran)
Plasti-Mach Corporation (Robert Rosen)
Portage Casting & Mold, Inc. (Kenneth Griep)
Solar Products Inc. (Michael Sirotnak)
Spartech Plastics (Larry Brooks)
Tempco Electric Water Heater Corp. (Dennis Padlo)
WORKSHOP FEES
| Registration
Fees |
Early
Registration
through 2/4/04 |
After
2/4/04 |
| SPE
Member |
$1125 |
$1225 |
| New/Renewing
SPE Member |
$1232 |
$1332 |
| Nonmember
|
$1275 |
$1375 |
GENERAL
INFORMATION
LOCATION:
The seminar portion will be held at the Crowne Plaza Hotel, 7050
Stemmons Freeway, Dallas Market Center, Dallas, TX 45247. The telephone
number is (214)630-8500 and fax number is (214)630-9486.
Driving Directions: North on I35 E, Exit 433B. Crowne Plaza is
on right just before Mockingbird Lane. South on I35 E, Exit 432B. U-turn
under freeway & stay on the access road, hotel is on right.
Area Airport Information: Dallas
Love Field (DAL )- Distance: 2 MI/ 3.22 KM W, Complimentary Airport
Shuttle, Taxi Fee: $6.00 (USD), Time by taxi: 7 min. DFW Internatnl
(DFW) - Distance: 12 MI/ 19.31 KM N, Taxi Fee: $26.00 (USD), Time by
taxi: 20 min.
Alt. Transportation: Yellow Checker Shuttle, Alt. Transportation
Fee: $15.00 (USD).
SUGGESTED ATTIRE:
Casual business attire is appropriate. Please be prepared for moderate
temperature variation in the seminar room.
CANCELLATIONS:
Cancellations received after February 20, 2004 are subject to a $100
administrative fee. Substitutions may be sent in place of the registrant
at any time with prior notification to SPE.
SPE reserves the
right to cancel a seminar or substitute instructors. If SPE should cancel,
they will contact the attendee as soon as possible prior to the scheduled
seminar. SPE is not responsible for penalty fees or any costs incurred
by the attendee due to the cancellation of a seminar.
All
forms of registration are considered binding and subject to all cancellation
policies. Check your confirmation to verify that you are registered
for the seminar/program requested. If you do not receive a confirmation
prior to attending, please call (203) 740-5403 to verify your registration.
All forms of
registration must contain payment, either by credit card or check, otherwise
the registration will not be processed. Checks should be made payable
to SPE Seminars in U.S. funds.
REGISTRATION
Register on-line: Online Registration
Form
Printable form to mail or fax
(pdf)
Register by fax: Complete the registration form, include payment
and fax to (203) 775-8490 Attn: Seminars.
Register by mail: Complete the registration form, include your
payment and mail to: Attn: Seminars, SPE, P O Box 403, Brookfield, CT
06804-0403. Registrations by mail must be received two weeks prior to
the program and will be processed, subject to availability in the program.
Register by phone: Call SPE at (203) 740-5403
All forms of
registration must contain payment, either by credit card or check, otherwise
the registration will not be processed. Checks should be made payable
to SPE Seminars in U.S. funds.
Registration
Fees: Registration fees includes course instruction, seminar manual,
transportation for tours, lunches, refreshment breaks, Welcome Receptions,
and dinner Tuesday evening at the Trail Dust Steakhouse. It does not
include hotel accommodations.
All forms of registration
are considered binding and subject to all cancellation policies. Check
your confirmation to verify that you are registered for the seminar/program
requested. Details regarding hotel, shuttle service and local area will
be sent with your confirmation. If you do not receive a confirmation
prior to attending, please call (203) 740-5403 to verify your registration.
REGISTRATION
IS LIMITED AND IS ON A FIRST COME, FIRST SERVED BASIS. EARLY REGISTRATION
IS HIGHLY RECOMMENDED!
|
