Thermoforming is a process for forming moderately complex shaped parts that cannot be injection molded because the part

is either very large or too expensive or has very thin walls. (Ebewele, 2000) It consists essentially of two stages: elevation of the temperature of a thermoplastic sheet material until it is soft and pliable and forming the material into the desired shape using one of several techniques. (Ebewele, 2000)

PROCESS DESCRIPTION From the foregoing discussion, it is evident that the basic steps in the thermoforming process involve a sequence of operations: loading the sheet or web through the system in increments and heating, forming, and cooling. Other secondary functions that may be integrated into the process include trimming and other finishing operations. Thermoforming machinery is categorized on the basis of the arrangement for performing these operations. In single station machines, the loading, heating, forming, cooling, and unloading operations are performed in succession. Consequently, even though these machines are versatile, they are characterized by comparatively long cycle times. With in-line machines, which are quite popular in the packaging industry, the different operations are performed simultaneously in a multistation in-line system. In this case, therefore, the cycle time is determined by the longest operation in the entire process. The third category of thermoforming machines is the rotary type, which is supported on a horizontal circular frame that has three work (and possibly other secondary stations for the loading unloading, heating, and forming (possibly secondary) operations. By rotating the cut sheets sequentially from station to station, the rotary machine configuration is well suited for high production rates. (Ebewele, 2000) Molds for the thermoforming process may be made of wood, metal, or epoxy and are relatively cheap. They are provided with vents to allow trapped air to escape and release possible pressure buildup. Temperature control, as we shall see in the following discussion, determines part quality. It is, therefore, crucial that mold temperature is controlled properly. The mold is consequently provided with channels for the passage of the cooling liquid. (Ebewele, 2000)

B. PROCESS VARIABLES Thermoplastic materials, in general, can be stretched when hot. However, the degree of success informing a part from a hot, stretched sheet material depends on the particular resin, its molecular weight, and processing conditions like forming temperature and speed. We recall that the thermal response of thermoplastic polymers depends first on whether the material is amorphous or crystalline and to some extent on their molecular weights. When heated, crystalline polymers undergo a rather abrupt phase transformation from the solid to the fluid state, while amorphous polymers undergo a more gradual transformation. For a given resin, the degree of fluidity depends on molecular weight and the processing temperature. The higher the molecular weight, the higher the melt strength and consequently the greater the capacity of the material to be deep-drawn, which is a necessary condition for the proper formation of intricate parts. On the other hand, materials that are too fluid at the forming temperature are susceptible to tearing, leading to the production of bad quality parts. Given the influence of forming temperature on part quality, it is necessary to ensure that sheets have a uniform temperature distribution. This also calls for a uniform sheet thickness. A variation in sheet thickness causes a non-uniform sheet temperature distribution resulting in uneven pulling and possible tearing of the sheet. It is also essential to recognize that variation of shrinkage with sheet orientation can generate forming problems. If there is excessive differential shrinkage due to sheet orientation, the pull from the clamping frames during forming becomes unbalanced and the sheet could be pulled out. (Ebewele, 2000)

is a method used to make thin-wall hollow products. In this process, two separate sheets are heated until hot and pliable. The sheets are indexed into the molding station, where they rest one just above the other. (see fig. 1) (Lokensgard, 2010) is a special process in which two thermoformed parts are bonded together during the process to form a hallow parts. This process requires the use of two cavity molds and two heating stations. Both sheets are heated simultaneously and transferred to the forming station. Typically straight vacuum forming procedures are used for both sheets into their respective cavities. (Fig. 2) After forming, but while the materials are still hot, the two cavity molds are forced together thus welding the two parts into one. (Fig. 3) A needle may be inserted to blow air into the hallow part

to further form the parts and provide more forming pressure. (Klein,2009) Foam may also be injected into the hallow part to make a foam filled structural part as a very tough plastic pallet. The pinch off area design is very important to obtain a solid weld between the two halves. (Klein,2009)

Figure 1 Twin-sheet forming: (a) heated sheets inserted between mold halves, (b) molds closed and sheet edges heat bonded, (c) compressed air inflates part and (d) manufacture part removed from mold. Vacuum draws the upper sheet into an upper mold cavity and the lower sheet into a lower mold. As the sheets stretch into the mold cavities, the mold halves close, sealing the two sheets together. Sometimes pressure may be introduced between the sheets to aid in forming and cooling. (Ashter, 2014)

Figure 2. Forming two parts

Figure 3. Molds Forced Together, Creates Welds

The art of twin-sheet forming is discussed and its growth in popularity is examined. Its structural potential due to its ability to incorporate internal ribs and bosses as well as metal reinforcing inserts is one reason, and when combined with pressure forming, twin sheet can produce parts with the definition and sharp corners of injection molding or structural foam. It can also make hallow parts that would only otherwise be possible with blow molding or rotomolding, and its tooling costs are low. POLYMERS THAT CAN BE USED IN TWIN-SHEET THERMOFORMING Almost all thermoplastics but most commonly used include ABS, PP, PS, PVC polyesters; others include acrylics, polycarbonate, cellulosic, nitrile resins.

PRODUCTS PRODUCED IN TWIN-SHEET THERMOFORMING Automobile, airline and mass transportation industries for such uses as auto headliners, fender walls, overhead panels, aircraft canopies; construction industry for exterior and interior paneling, bathtubs, shower stalls; outdoor signs; appliances, e.g., refrigerator liners, freezer panels; packaging trays for meat packing, egg cartons, fast-food disposables and carry outs, blister packages, suitcases, tote boxes, cups, horticultural trays, luggage; furniture panels, glove compartment boxes; meat, poultry, and egg containers; fast-food containers, blister packs, container lids; cookie, candy, pastry and other food packages.

EXAMPLE OF A PROCESS INVOLVING TWIN-SHEET THERMOFORMING (MANUFACTURE OF VEHICLE HEADLINERS) In the process a first sheet and second sheet of SuperLite material are mounted onto respective frames. The frames transfer the sheets into an oven, where they are heated to a desired temperature using IR. The first sheet is combined with a cover-stock material using compression molding forming a covered first headliner part. The covered first headliner part is then transferred to a second mold station. The second sheet is heated and then transferred from the oven to the second mold station where it is vacuum-formed on the upper half mold, forming a second headliner part. The upper and lower mold halves are pressed together fusing and sealing the first and second headliner parts into a unified part. The unified part is then unloaded and trimmed as necessary forming a headliner. The Super Lite material used to form the headliner is a sheet of low pressure, thermoformable, thermoplastic composite comprised of polypropylene and long chopped glass fibers.

Figure 5. Steps in the manufacture of vehicle headliners using twin-sheet thermoforming

Fig. 5 is a schematic drawing illustrating the process of forming a headliner using a single model to vacuum form a first and second sheet of a thermo plastic composite, and then to unify the two molded sheets. A first sheet is paced in a frame and then moved into an oven. The oven is either an IR, air impingement, hot air, RF or a combination thereof. The IR ovens offer the advantage of requiring little floor space, no ventilation and profiling the heat intensity. Generally electric IR is preferred to gas IR as no exhaust gas ventilation is required. A medium wavelength infrared (2-4 microns) is commonly employed. Heating time is about 40-60 seconds, which is sufficient to warm the sheet to about 180 C to 225 C. The sheet material employed in a typical headliner is 2.5 mm thick, and has a weight from about 750 to about 950 GSM. When the first sheet reaches the desired temperature it is transferred into the mold as shown in Step 2 of Fig.5 where it is vacuum formed on the lower half mold forming a first headliner part, and the second sheet, loaded on a second frame, is transferred into the oven. Step 3, the heated second sheet is transfer into the mold, where it is vacuum formed on the upper half mold, forming a first headliner part. In step 4, the mold is closed in the compression mode. The upper and lower half molds have matching surfaces, which regionally cause the first and the second headliner parts to be compressed against each other, therein fusing regions of the two headliner parts forming a unified part. The unified part has at least one interior compartment, which provides impact cushioning. In step 5, the mold is opened and the unified part is ejected and transferred into the trimming and finishing station. In step 6, the selvage is removed and finishing steps are completed, such as welding, attachment of fastening element or modification of the interior compartment is completed. For instance a modification of the compartment would be to fill it with foam.

REFERENCES:
Ashter, S. A. (2014) Thermoforming of Single and Multilayer Laminates: Plastic Films Technologies, Testing, and Applications. Elsevier: 225 Wyman Street, Walthan, USA Ebewele, R.O.(2000) Polymer Science and Technology. CRC Press LLC: 2000 N.W. Corporate Blvd., Boca Raton, Florida Klein, P. (2009) Fundamentals of Plastics Thermoforming. Morgan and Claypool Publishers: USA Lokensgard, E. (2010) Industrial Plastics: Theory and Applications. Delmar, Cengage Learning: New York, USA