Materials Engineering

Polymer Processing 3 Thermoforming and Summary

Dr. Michael Conry

michael.conry@ucd.ie

Vacuum Forming
Dates back to 1950s. Relatively simple technique: 1. Thermoplastic sheet is clamped over a negative mould 2. Sheet is softened by heating 3. Vacuum is drawn within mould through vents 4. Sheet is drawn into contact with mould and allowed to cool Once the sheet is cooled it can be removed from the mould.

Dr. Michael Conry

michael.conry@ucd.ie

Heated Thermoplastic sheet Clamp Clamp

Thermoplastic sheet Clamp Clamp

Vents

Mould

Vents

Mould

Dr. Michael Conry

michael.conry@ucd.ie

Vacuum Forming
Disadvantages: Wall thickness varies Need to do a lot of nishing work waste (time and material) Polymer is heated twice (once to make sheet, second time to mould sheet) Limited range of shapes available Detail not great due to low pressure differential However, the process is not without its uses. . . Advantages/Applications: Technique is simple and has low capital cost Suitable for large formings Widely used for thin walled packaging (e.g. for sandwiches, electronics, blister-packs).
Dr. Michael Conry 4 michael.conry@ucd.ie

 Useful for short-runs or prototypes

Dr. Michael Conry

michael.conry@ucd.ie

Vacuum Forming
This is potentially a very simple technique, and can be implemented at little cost, even by hobbyists: http://www.studiocreations.com/stormtrooper/main.shtml

Dr. Michael Conry

michael.conry@ucd.ie

Dr. Michael Conry

michael.conry@ucd.ie

Vacuum Forming
Some notes Tool/mould can be negative or positive (see previous slides). Negative gives good external detail, positive give good internal detail. Tool can be made of wood, metal, plaster or epoxy. Vacuum gives pressure differential of about 1 atm. Can add positive pressure on other side for total differential of up to 10 atm. Better output but costs increase. Sheet material needs to have reasonable form stability when heated needs to have a fairly high relative molecular mass. E.g. Polystyrene, Acrylics, PVC, Polypropylene Pre-stretch can be employed to give better distribution of material in wall and to produce deeper formings. E.g. Vacuum bubble snap back technique.
Dr. Michael Conry 8 michael.conry@ucd.ie

Vacuum Forming
Vacuum Bubble Snap Back Technique
1 2

Heated Thermoplastic +ve pressure

Air relief valve AIR

4
Vacuum

+ve pressure

+ve pressure

Dr. Michael Conry

michael.conry@ucd.ie

Blow Moulding
This technique is used to make simple parts like plastic bottles in very high volumes at very low cost. Procedure begins with a parison which is a plastic cylinder. 1. This is closed at one end, 2. it is softened with heat 3. then it is inated while inside a mould 4. Having taken on the shape of the mould the part cools and is removed. Two types of blow moulding will be mentioned here: Extrusion Blow moulding Injection Blow moulding

Dr. Michael Conry

10

michael.conry@ucd.ie

Blow Moulding
Extrusion Blow Moulding
1
Mould half

2 Pinched Mould half

off Parison Air Gas Nozzle Die

Extrudate

Gas Nozzle Die Mould half

Mould half

3
Note that Extruder is located to the right hand side of the die in the first frame of this diagram. Cavity Air Gas Nozzle

Dr. Michael Conry

11

michael.conry@ucd.ie

Blow Moulding
Injection Blow Moulding Parison is injection moulded onto a steel rod. Rod and Parison are then inserted in to a mould. The parison is inated and takes up shape of the mould. Finally completed part can be ejected.
Injection Moulding Machine

Mould Rod

Polymer AIR

Dr. Michael Conry

12

michael.conry@ucd.ie

Other Thermoforming
Thermoforming with Matching Moulds This is similar to Vac-Forming but produces more detailed and controllable product
Heated thermoplastic sheet Mould Half

Mould Half

Mould Half

Mould Half

Dr. Michael Conry

13

michael.conry@ucd.ie

Other Thermoforming
Compression Moulding Used for thermosetting polymers. A metred amount of polymer is placed in the mould cavity. Two halves are closed (like in matching mould setup). Mould is then heated allowing the thermoset to cure. Advantages: Polymer ows short distances, reducing frozen in stresses No gates less likely to have weakspots Moulds are cheaper to make and maintain No need to design sprue and runner layout

Dr. Michael Conry

14

michael.conry@ucd.ie

Mould Half

Heat applied, Thermoset cures. Mould Half

Mould Half Liquid thermoset

Mould Half

Dr. Michael Conry

15

michael.conry@ucd.ie