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Higher Institute for Plastics Fabrication

WORKBOOK
for

Thermoforming
Practical Course

Prepared by

Thermoforming Department
1st Edition 2009
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ACKNOWLEDGEMENT

In its program to continuously improve the quality of instructions at the


Higher Institute for Plastics Fabrication, the Curriculum Steering Committee
initiated the creation of the workbooks for all practical courses being offered
in the Institute. The Committee is headed by Dr. Khaled Al-Ghefaili, and the
members are Dr. Ahmad Al-Ghamdi, Mr. Hiroshi Takeshita, Engr. Issa AlKhormi, Mr. Sumio Iwase, Mr. Kazuhiko Sawada, Mr. Sanjay Rawat, Mr.
Zakaria Musa, and Mr. Virgilio Calpe.

This is the HIPF Workbook for Thermoforming Practical Course.

The

contents of this workbook were compiled through the efforts of the members
of the Thermoforming Department, namely, Antonio Pasaoa (Head of the
Department), Rameshwar Selukar, Joy Falaminiano, and Koichi Inagaki
(Japanese Expert Adviser).

Editing, formatting and design by Virgilio

Calpe.

April 2009

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TABLE OF CONTENTS
Introduction .

Course Objectives .

Grades Summary Sheet ...

Workshop Activities
Activity 1Introduction Basic Principles of Thermoforming ..

Activity 2Thermoforming General Safety Instructions .

16

Activity 3Materials and Their Applications ...

30

Activity 4The Thermoforming Machine and Mold .

40

Activity 5Thermoforming Methods & Processes

53

Activity 6Manpower and Standard Operating Procedures

64

Activity 7Product Quality, Defects and Troubleshooting ..

74

Activity 8Handson and Practical Training (1) ...

83

Activity 9Handson and Practical Training (2) .

89

Activity 10Handson and Practical Training (3)

95

Glossary .

101

References ...

118

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INTRODUCTION
As the demand for plastics continuously grow through the years, invention of
many plastics manufacturing processes took place. Thermoforming is one of
them.
Thermoforming is the process of forming a thermoplastic sheet into a threedimensional shape by heating it to render it soft and formable, then applying
different vacuum and pressure to make the sheet conform to the shape of a
mold or die.
Initially, thermoforming was more of manual operation and used for very
specific and limited application and selected materials with only single
cavity and longer cycle time. But due to technological breakthrough and
rapid development through the years, thermoforming has improved and, so
far, is now one of the best improved technology in terms of efficiency.
In today's rapid research and product development, consumers are working
continuously with major resin suppliers, rigid sheet extruders and original
equipment manufacturers in developing high-tech, multi-layered plastic
systems, which equal or outperform traditional materials in many
applications. Thermoforming production processes nowadays are employed
for engineering applications to an extent that only a few decades earlier
would have been deemed impossible. Continually improving thermoplastics,
in conjunction with the most modern machinery, have not only increased
output rates but also the quality and precision of the moldings.
Besides traditional applications, thermoforming has conquered an important
market share with the pressure forming method of packaging particularly the
food packaging industries.

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COURSE OBJECTIVES
The purpose of this workbook is to enable the trainees to understand and
carry out important activities in relation to Thermoforming. Focus will be on
the functions in Thermoforming and the terminologies used in the industry.
Upon completion of this course, the trainee shall be able to:

Have awareness in the importance of Thermoforming Plastic Fabrication


technology.

Discuss and explain the concept,


Thermoforming plastic fabrication.

To operate the Thermoforming machine safely and appropriately.

theories

and

practices

of

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GRADES SUMMARY SHEET


Trainee Name: _________________________ Group: ________
Semester ___ School Year ___________

ACTIVITIES

GRADE

Activity 1Introduction: Basic Principles of Thermoforming


Activity 2Thermoforming General Safety Instructions
Activity 3Materials and Their Applications
Activity 4The Thermoforming Machine and Mold
Activity 5Thermoforming Methods & Processes
Activity 6Manpower and Standard Operating Procedures
Activity 7Product Quality, Defects and Troubleshooting
Activity 8Handson and Practical Training (1)
Activity 9Handson and Practical Training (2)
Activity 10Handson and Practical Training (3)
AVERAGE GRADE

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WORKSHOP ACTIVITY #1

Introduction: Basic Principles of Thermoforming


THEORETICAL BACKGROUND
In Thermoforming, the plastic sheet material in rolls will be thermally
heated to make it soft and formable, and then vacuum and/or pressure is
applied to form the shape of the mold. The formed products will be cut &
separated from the skeleton or the runner while the molded products will be
collected and packed accordingly. The runner or skeleton will be crushed
and pelletized to convert it back again into pellet form which will then be
mixed with virgin materials, normally at 20-30% ,to re-process back again
into sheets.

The Six (6) Main Processes of a Thermoforming Machine:


1. Unwinding or Unreeling of Sheet RollThe sheet is unrolled to dispense
the material into the feed zone. Using a guided chain, the sheet is
conveyed and is passed through the heater.
2. HeatingThe sheet is heated to make it soft at a set parameters.
3. Forming (Shaping & Cooling)The soft sheet is formed to the shape of
the mold and then allowed to cool.
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WORKSHOP ACTIVITY #1Introduction: Basic Principles of Thermoforming

Theoretical Background continued


4. CuttingThe molded product is separated from the runner or skeleton
5. StackingThe product is collected in a stack and then ejected to the
conveyor for packing
6. Winding of skeletonThe skeleton is collected and removed for
recycling.
Thermoforming process is different from the other plastic fabrication
processes because its raw material is not the usual pellets being melted
through the use of extruder to produce the desired shape using a die or molds
but rather using the finished product of Sheet Extrusion which is the rolled
sheet as its raw material.

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WORKSHOP ACTIVITY #1Introduction: Basic Principles of Thermoforming

Theoretical Background continued

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WORKSHOP ACTIVITY #1Introduction: Basic Principles of Thermoforming

Theoretical Background continued


The Thermoforming industry started from Vacuum Forming using rigid PVC
sheet. Since polystyrene (PS) was developed, PS sheet penetrated rapidly the
Thermoforming industry due to easier formability. Process development for
Pressure Forming and Plug Assist Forming expanded further the industry.
Recently, polypropylene (PP) sheet is used in applications, in which heat
resistance or oil resistance is required, where PS sheet can not be used.
There are actually many thermoforming processes now available in the
market but the three most commonly used basic processes are:
1. Vacuum Forming ProcessThe oldest and cheapest process in terms of
equipment cost.
2. Pressure Forming ProcessThe fastest among the processes in terms of
production speed (more than three times that of Vacuum Forming) due to
higher pressure.
3. Plug-Assist Forming ProcessFor deep draw shapes like drinking cups
& bowls.
Applications:
Packaging trays, cups, bowls, automotive panels, car roof top, boat hulls,
large panels, spa baths, kitchen sinks possibilities are endless

One of the most important industries that thermoforming serves, however, is


the packaging industry.
Advantages of Thermoforming are:
1. Cheaper equipment and mold cost
2. Higher productivity due to its high speed
3. Thinner wall product, therefore, lesser material consumption and cheaper
products
4. Lower production cost due to above features
The only disadvantage of thermoforming so far is its high scrap rate due to
its inevitable runner being generated as part of it production processes.

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WORKSHOP ACTIVITY #1Introduction: Basic Principles of Thermoforming

OBJECTIVES OF THE ACTIVITY


1. To learn the basics of the Thermoforming processes
2. To identify the main parts of Thermoforming machine and their functions

PROCEDURE
PART IThe Basics of Thermoforming Processes
1. Go to the Workshop floor (per group) and observe how the
Thermoforming machine run. The process will be explained to you by
your Instructor.
2. Using the data sheet form, list down the different stages or functions of
the Thermoforming machine.
3. Using a stop watch, take the actual time needed to complete each of the
stages and compute for the total cycle time.
4. Look at the monitor of the control panel and compare the total cycle time
(actual cycle time versus the recorded cycle time in the machine).
5. Write down your observation in your data sheet.
PART IIThe Six (6) Main Parts of Thermoforming Machine
1. Using the drawing of Thermoforming machine in your data sheet, label
the six (6) main parts of the machine in the space provided.
2. Write down the corresponding functions of each of the six main parts of
the Thermoforming machine.

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DATA S H E E T
ACTIVITY #1Introduction: Basic Principles of Thermoforming
TRAINEE NAME

GROUP NO.

PART IThe Basics of Thermoforming Processes


STAGES OF
THERMOFORMING

FUNCTION

CYCLE TIME

1.
2.
3.
4.
5.
6.
TOTAL RECORDED CYCLE TIME (STOP WATCH)
TOTAL CYCLE TIME FROM CONTROL PANEL

PART IIThe Six (6) Main Parts of Thermoforming Machine

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WORKSHOP ACTIVITY #1Introduction: Basic Principles of Thermoforming

QUESTIONS & EXERCISES


Select the correct answer.
1.

Thermoforming is the process of forming a thermoplastic sheet into a


desired shape, by __________ heating it to make it soft and formable,
then applying vacuum and/or pressure to make the sheet formed to the
shape of the mold.
a. mechanically
b. conductively
c. thermally
d. electrically

2.

In thermoforming process, after the forming takes place, the sheet is


held against the mold surface until __________.
a. heated
b. cooled
c. warmed
d. shaped

3.

In thermoforming process, after the forming takes place the formed


product parts are then __________ off from the sheet.
a. trimmed
b. stacked
c. ejected
d. contracted

4.

In thermoforming process, after the forming, cutting and punching take


place, the punched out sheet or the runner is usually __________,
mixed with virgin material, and reprocessed into usable sheet again.
a. reground
b. scraped
c. recycled
d. as is

5.

__________ is the one of the four resources of thermoforming process.


a. Water
b. Electricity
c. Manpower
d. Compressed air

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WORKSHOP ACTIVITY #1Introduction: Basic Principles of Thermoforming

QUESTIONS & EXERCISES continued


6.

__________ is a device used to make or transform a thermoplastic


sheet into any desired shape using a mold by applying heat and
pressure.
a. Sheet extrusion machine
b. Advanced molding machine
c. Thermoforming machine
d. Injection molding machine

7.

One of the main functions of the mold is to __________ the material to


the surfaces of the mold.
a. receive and distribute
b. heat
c. cut
d. separate

8.

Thermoforming machine process arrangement is designed in such a


way that the __________ station comes after the heating work station
to form the shape of the mold.
a. winding
b. stacking
c. forming
d. heating

9.

Besides traditional applications, thermoforming has conquered an


important market share of packaging with the __________ forming
method.
a. pressure
b. vacuum
c. simple
d. plug-assist

10.

The only disadvantage of thermoforming so far is its high _______ rate


due to its inevitable runner being generated as part of it production
processes.
a. economical
b. scrap
c. productivity
d. rejection

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WORKSHOP ACTIVITY #1Introduction: Basic Principles of Thermoforming

CONCLUSION & RECOMMENDATIONS

___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
________________________
DATE: __________________

TRAINEES SIGNATURE

INSTRUCTORS COMMENTS

TRAINEES GRADE
FOR THIS ACTIVITY

________________________
DATE: __________________

INSTRUCTORS SIGNATURE
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WORKSHOP ACTIVITY #2

Thermoforming General Safety Instructions


THEORETICAL BACKGROUND
Respect for
Human Life

The Lives of Workers are Protected

A Safe workplace has positive effects on


Safety
Management

Corporate
Management

operations of the company.

A safety-oriented corporation is trusted


Social
Credibility

by Society.

Figure 2.0Objectives of Safety Management

A company manages safety to achieve the objectives shown in Figure 2.


Safety when it comes in Manufacturing environment has the following
meanings:

There are no accidents that result in personal injuries.

There are no accidents that result in damage to property such as


facilities, machinery, equipment, materials, or products.

There are no accidents that affect residents and areas around the
factory.

The factory is managed to ensure that the above conditions are


maintained continuously.

Why Is Safety Important?


The importance of safety at work place can't be over exemplified. It is
mostly felt in factories where the laborers are exposed to sustained risk in
their daily operations. Adaptation of safety measures not only ensures safety
of the life of the workers, but also of their families and their dependents.

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WORKSHOP ACTIVITY #2Thermoforming General Safety Instructions

Theoretical Background continued


2.1.2 Who is Responsible for Safety?
Factory
Company
Executives

Manager/s

Supervisor/s

Personnel
/ Machine
Operators

Figure 2.1Safety Responsibility

From the employer down to the lowest level of position in the company, each
person has his own safety responsibilities. It is a requirement in an corporate
institution that all employees are properly instructed and supervised in the
safe operation of any machinery, tool, equipment, process, or practice which
they are authorized to use or apply.
Basically, the employer must provide training to each employee to do each
aspect of their job safely, and must provide adequate supervision of each
employee to assure that the training was effective and that the employees are
following safe procedures.

Thermoforming Machine Safety


As an operator, you must always follow the signs and symbols, and you must
be safety conscious to avoid accident. Ignorance is not an excuse when
accident happens. Therefore, developing a safety habit is the best policy that
should be adopted by everybody.

Remember, the life you save, maybe your own!


Safety Instructions
1. Machine is a potential source of danger if it is operated by untrained
operator.
2. The general directives on work safety, accident prevention must be
complied as per the Instructors instructions.

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WORKSHOP ACTIVITY #2Thermoforming General Safety Instructions

Theoretical Background continued


3. Always work with concentration and be conscious of safety aspects!
4. Prior to starting work, check the orderly condition of the machine, in
particular the operability of the safety devices.
5. Clarify any queries or unclear matters you may have regarding the work
with and on the machine before starting work!

Warnings and Symbols


The following designations and symbols are used to convey important
information.
Caution:
Warning of a general source of danger, the consequence of
which can be personal injury and/or damage to property
Danger caused by electrical current or voltage!
Warning against injury such as electric shock through
electrically conducting devices.
Hot parts or surfaces!
Warning against danger of burns from parts or surfaces
that have high temperatures even after the machine has
been switched off.
Not allowed for person with cardiac pacemaker!
Persons with a cardiac pacemakers are not allowed to work
on subassemblies that bear this symbol because there is
danger from noise influences due to the static charging of
the plastics film.
Stay Away!
Dont move close to the part, it is dangerous area.

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WORKSHOP ACTIVITY #2Thermoforming General Safety Instructions

Theoretical Background continued

Safety Measures

Emergency Buttons
Actuation of an EMERGENCY STOP button
interrupts the control voltage, switches off the
compressed-air supply and de-aerates the
compressed-air network up to the inlets of the
solenoid valves.

Mechanical Locking of the Sliding Doors


Safeguard against reaching into the machine while
it is running. Machine cannot be switch ON O
when sliding door is open; it also advices not to
open the sliding door during operation.

Hand Lever with Securing Pin


For limiting the travel range of the reel mounting,
in order to avoid the danger of crushing.

Safety Limit Switch on the Door of the Skeletal


Re-winder
Safeguard against reaching into the rotating
skeletal mounting.

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WORKSHOP ACTIVITY #2Thermoforming General Safety Instructions

Theoretical Background continued

Safety Measures continued

Back-pressure valves in the connections of the


pneumatic cylinders on pneumatically operated
machine parts
To prevent these machine parts from moving when
the machine is at a standstill.

An electrical pressure switch, with a fixed setting of 4 bar


If the operating pressure falls below this value, the
control voltage is switched off and the compressed
air system is de-aerated.

Safety valves with a spring-centered, disabled


middle position for the top and bottom frames
of the forming station
To safeguard against any undesired movements.

See Actual
Machine
Part

Mechanically lockable main switch on the


switch cabinet.
If the main switch is in position "0", all electrical
subassemblies (control unit, heaters, electronic system) are de-energized. The compressed-air network
is deaerated up to the inlets to the solenoid valves.

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WORKSHOP ACTIVITY #2Thermoforming General Safety Instructions

Theoretical Background continued

Special Danger and Measures

CO2 Fire Extinguisher


Fires can occur if the plastic being molded is
overheated.

Gases and Vapors


Depending on the plastics to be molded, gases and
vapors can be formed at the heating-up temperature. Therefore, consult your Instructors or supervisor, should you need to make necessary provision
for suitable extraction.

Technical Data Sheet (Technical Bulletin)


Important to keep the Technical Data / Safety Data
Sheet from the Thermoforming Sheet manufacturer / supplier, in particular the permissible maximum temperature values. Certain plastics may
burn explosively on heating, e.g., cellulose-based
plastics. Foam films may be processed only if they
are foamed with non-inflammable gases.

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WORKSHOP ACTIVITY #2Thermoforming General Safety Instructions

Theoretical Background continued

Special Danger and Measures continued


Do not touch the heaters!
Heater

There is a danger of burning the heaters even after


the main switch had been switched off.

Compliance with the Safety Standards


d
ve
o
r
p
Ap

If the machine is linked to special devices (e.g.,


filling devices, crusher device, packers), compliance with the safety standards attachment of these
devices must be properly observed.

Personal Protective Equipment (PPE)


a. Wearing of an appropriate protective helmet:

Auxiliary equipment temporarily attached to the machine at


head height during tool changing poses a risk.

b. Wearing of an appropriate safety shoes (have a high anti-static


action) :

During the thermoforming process, the guidance, unwinding,


steering and winding of thermoplastic materials can create very
high static charges, which cannot always be discharged safely.

c. Wearing of an appropriate protective gloves (with sufficient


level of protection):

Danger of cuts from sharp edges

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WORKSHOP ACTIVITY #2Thermoforming General Safety Instructions

OBJECTIVES OF THE ACTIVITY


1. To learn the basics of safety and safety signs
2. To develop safety awareness among trainees and learn the most common
hazards that may lead to injuries like amputations, lacerations, crushing
injuries and abrasions in Workshop and Machine Operations.

PROCEDURE
PART ISafety and Warning Signs
1. Walk around the Workshop area and locate all the safety signs.
2. Observe the Machine area for unsafe points and try to identify safety /
warning signs found.
3. In your data sheet, correctly write the names of the safety devices and
warning signs in the pictures.
PART IISafety Devices Commonly Found in Thermoforming Machines
1. Walk around the Thermoforming Machine and try to locate all the safety
devices present.
2. In your data sheet, write down the names of the safety devices and their
functions.

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DATA S H E E T
ACTIVITY #2Thermoforming General Safety Instructions
TRAINEE NAME

GROUP NO.

PART ISafety and Warning Signs


SAFETY DEVICES AND SAFETY SIGNS IN THE

HIPF Thermoforming area

1.

2.

3.

4.

5.

6.

7.

8.

9.

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DATA S H E E T
ACTIVITY #2Thermoforming General Safety Instructions
TRAINEE NAME

GROUP NO.

PART IISafety Devices Commonly Found in Thermoforming Machines

1. ________________

2. ________________

3. ________________

4. ________________

5. ________________

6. ________________

7. ________________

8. ________________

9. ________________
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Report Form - Page 3 of 6

WORKSHOP ACTIVITY #2Thermoforming General Safety Instructions

QUESTIONS & EXERCISES


Part IFill in the blanks from the given choices.
1. What are accidents?
Accidents usually result from a combination of factors that includes both
_____________________machine condition and ___________________
human actions.
2. Write down the names of PPE equipment to be used for each category.
Eye - ___________________________________
Face - __________________________________
Head - __________________________________
Feet - ___________________________________
Hands and arms - _________________________
Bodies - _________________________________
Hearing - ________________________________
3. A _________ colored warning triangle with black graphical symbol
indicates what the hazard is.
4. A _________ colored circle-with-slash with black graphical symbol
indicates a prohibited action to avoid the hazard.
5. A __________ colored mandatory action circle with white graphical
symbol indicates an action to take to avoid the hazard.

plugs, earmuffs / Yellow / Red / Blue


hazardous / careless / safety glasses, goggles / face shields / hard hats / safety shoes /gloves / vests / earANSWERS:

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WORKSHOP ACTIVITY #2Thermoforming General Safety Instructions

QUESTIONS & EXERCISES continued


Part IIChoose the correct answer.
1. Which is the correct shape and color for a Prohibitory Sign?

2. Which is the correct color and shape for a Mandatory Sign?

3. Which is the correct color and shape for a Fire Sign?

4. Which is the correct color and shape for a Fire Sign?

5. Which is the correct color and shape for an Information Sign?

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WORKSHOP ACTIVITY #2Thermoforming General Safety Instructions

QUESTIONS & EXERCISES continued


6. Which is the correct meaning of the given sign below?
a.
b.
c.
d.

No naked lights
Smoke-free rest area
No smoking
Smoking allowed

7. What do blue and white safety signs tell you?


a. Things you must not do
b. Things you must do
c. The nearest fire exit
d. There is a hazard in the area
8. Which is the correct image below which represents Danger, electricity?

9. When used on site what does this sign mean?


a.
b.
c.
d.

Mandatory
Safe condition
Warning
Prohibited

10. What is the correct meaning of this sign?


a.
b.
c.
d.

Ear protection may be worn


This is a noisy area
Caution, deaf people nearby
Ear protection must be worn

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WORKSHOP ACTIVITY #2Thermoforming General Safety Instructions

CONCLUSION & RECOMMENDATIONS

___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
________________________
DATE: __________________

TRAINEES SIGNATURE

INSTRUCTORS COMMENTS

TRAINEES GRADE
FOR THIS ACTIVITY

________________________
DATE: __________________

INSTRUCTORS SIGNATURE
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WORKSHOP ACTIVITY #3

Materials and Their Applications


THEORETICAL BACKGROUND
As an operator, you must always know the material properties and
processing conditions such as temperature, density, shrinkage, and other
factors, so that it would be easy to set the processing parameters when using
different thermoforming machines and molds.

What are Plastics?

Plastics are man made chemicals extracted mainly from petroleum.

They are basically composed of hydrocarbons: groups of linked hydrogen


and carbon atoms. (Imagine them as a small train and carriage!)

Most plastics are made up of long chains of hydrocarbons. (Identical


small trains joined together to form one very long train.)

More than 50,000 molecules (long trains) may be joined in chains to


produce polyethylene (or polythene).

Very long straight or branched chains are present in thermoplastics: for


example, polyethylene and polystyrene.

Thermoplastics always soften when heated and harden when cooled


down.

This makes these plastics ideal for the vacuum forming process.

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WORKSHOP ACTIVITY #3Materials and Their Applications

Theoretical Background continued

POLYSTYRENE (PS)
Polystyrene can be transparent or can be made to take on various colors. It is
economical and is used for producing plastic model assembly kits such as
cell phones frames, CD "jewel" cases, and many other objects where a fairly
rigid, economical plastic is desired. However, its major application is in the
food packaging industries.

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WORKSHOP ACTIVITY #3Materials and Their Applications

Theoretical Background continued


Polystyrenes are classified into two types.
1. GPPS - General Purpose Polystyrene

Main characteristics: transparent, stiff, and brittle

GPPS is very stiff but brittle, and highly transparent (clear) glassy
material. Due to high gloss and sparkling appearance, it is widely
used in thermoforming process to produce cups and trays with glossy
surface.

GPPS is used as surface layer for multi-layer sheet combined with


HIPS.

2. HIPS - High Impact Polystyrene

Main characteristics: high impact, opaque

HIPS is produced by physically adding rubber during polymerization


process of GPPS to make it more impact-resistant.

High Impact Polystyrene is rubbermodified GPPS.

HIPS is particularly suitable for thermoforming because of its rigidity


and high impact strength which means that it can be formed,
punched, and sawn without difficulty.

Typical raw materials for PS sheet produced by SABIC:

Melt flow index


Izod Impact Strength

GPPS PS125

HI-PS PS330

Transparent

Opaque

7.0 g/10min

4.0 g/10min

12.0 J/M

110.0 J/M

Typical PS sheet which can be used for Practice training:


Three layer PS sheets:

GPPS / HIPS / GPPS


GPPS / (HIPS + Regrind) / GPPS

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WORKSHOP ACTIVITY #3Materials and Their Applications

Theoretical Background continued


POLYPROPYLENE (PP)

The second important material for thermoforming is polypropylene, a


plastic material synthesized by stereo-regular polymerization of
propylene using Ziegler-Natta catalyst.

It is the highest volume polymer in the world

Main characteristics: lightweight, transparent, heat resistant, chemical/


oil resistant, low in cost.

Types of PP used in Thermoforming:

Isotactic polypropylene
- Crystalline plastics

Isotactic PP has three kinds:


1.

PP Homopolymer
- Transparent, brittle at low temperature

2.

Block copolymer with ethylene


- Opaque, High impact at low temperature

3.

Random copolymer with ethylene


- More transparent, less stiff

Key Properties of PP Used in Thermoforming:


1. Higher melt viscosity to avoid excess sagging in the Heating Station.
- PP grade with lower melt flow rate is selected.
2. Depend on customers need.
-

for transparent & glossy need: homopolymer or random


copolymer is selected.

for high impact at low temperature without transparency need:


block copolymer is selected.

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WORKSHOP ACTIVITY #3Materials and Their Applications

Theoretical Background continued


Typical PP sheet used for Practice Training
Raw material for PP sheet

SABIC PP 83EK10
Melt flow rate :1.2g/10min.
Izod Impact

:No break

PP sheet
Monolayer PP sheet
Three layer PP sheet: PP/PP +Regrind/PP

Importance of Recycling in Thermoforming


In thermoforming process, about 20 to 50% of plastic is generated as waste
after the cutting process depending on product design, such as Cup or Bowl.
The residual sheet after cutting called skeleton is processed in a recycling
machine to crush and pelletize.
The pellets from the recycling machine is fed back into the sheet extruder to
make a sheet.
Summary
The two kinds of plastics used in Thermoforming process are PS and PP.
Recycling is very important in Thermoforming.
PSAmorphous structure gives easier formability. Majority among plastics
used in Thermoforming is PS.
PPCrystalline structure gives superior characteristics such as higher heat
resistance and oil resistance. However, some difficulties in thermoforming
include sagging in the heating station and higher shrinkage rate in the
forming station.

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WORKSHOP ACTIVITY #3Materials and Their Applications

OBJECTIVES OF THE ACTIVITY


1. To give a brief review of the characteristics of plastics.
2. To discuss the two major types of plastics and their characteristics that is
commonly used for the plastics manufacturing sector.
3. To know the importance of each material and their applications to the
Thermoforming Industry.

PROCEDURE
1. In the classroom, bring two pieces of water cups, one PP and one PS.
Try to observe the difference in characteristics between polypropylene
(PP) and polystyrene (PS).
2. In the Machine site, observe behavior of each material (PS and PP)
during processing and try to note the differences.
3. In your Data sheet, write your observations for each material (PP and
PS). Define their characteristics when it is being use in thermoforming
application.

Page 35

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DATA S H E E T
ACTIVITY #3Materials and Their Applications
TRAINEE NAME

GROUP NO.

Observations on Thermoforming Materials


POLYPROPYLENE (PP)
_________________________________________________________________________
_________________________________________________________________________
_________________________________________________________________________
_________________________________________________________________________
_________________________________________________________________________
_________________________________________________________________________
_________________________________________________________________________
_________________________________________________________________________
_________________________________________________________________________

POLYSTYRENE (PS)
_________________________________________________________________________
_________________________________________________________________________
_________________________________________________________________________
_________________________________________________________________________
_________________________________________________________________________
_________________________________________________________________________
_________________________________________________________________________
_________________________________________________________________________
_________________________________________________________________________

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WORKSHOP ACTIVITY #3Materials and Their Applications

QUESTIONS & EXERCISES


Choose the correct answer.
1. What are the (2) two major categories of Thermoplastic Materials?
a. (Semi-) Crystalline & Amorphous
b. Polystyrene & PVC
c. Polystyrene
d. Thermoset & (Semi-) Crystalline
2. To which thermoplastics category does polypropylene and polyethylene
belong?
a. Amorphous
b. Thermoplastic Elastomer
c. (Semi-) Crystalline
d. None of the Above
3. A commonly used plastics material for thermoforming.
a. polyacetal
b. teflon
c. PET
d. nylon
4. Which material is recyclable?
a. Polystyrene
b. Epoxy resin
c. Phenolic resin
d. Polyester
5. What material is characterized to be translucent crystalline polymer that
exhibits high stiffness?
a. Epoxy resin
b. Polypropylene
c. Phenolic resin
d. Thermosets
6. What are the 3 types of polystyrene?
a. GPPS, HIPS, Expandable PS
b. Epoxy, Polyester, Polypropylene
c. Polyimides, Polypropylene, Polyvinyl Chloride
d. Polyacetate, Polycarbonate, Polypropylene
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WORKSHOP ACTIVITY #3Materials and Their Applications

QUESTIONS & EXERCISES continued


7. What is the general term for a wide range of synthetic or semi-synthetic
polymerization products?
a. Plastic
b. Polypropylene
c. Scrap
d. Recycling Process
8. Higher melt viscosity leads to excessive sagging in the Heating Station.
Hence, PP grade with lower melt flow rate is selected for thermoforming.
a. True
b. False
9. High Impact Polystyrene is rubbermodified GPPS.
a. True
b. False
10. Thermoformed products are also used in automotive sector.
a. True
b. False

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WORKSHOP ACTIVITY #3Materials and Their Applications

CONCLUSION & RECOMMENDATIONS

___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
________________________
DATE: __________________

TRAINEES SIGNATURE

INSTRUCTORS COMMENTS

TRAINEES GRADE
FOR THIS ACTIVITY

________________________
DATE: __________________

INSTRUCTORS SIGNATURE
Page 39

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WORKSHOP ACTIVITY #4

The Thermoforming Machine and Mold


THEORETICAL BACKGROUND
The Components of a Thermoforming Machine - Illig RV53b

Thermoforming Machine is a device use to make or transform a


thermoplastic sheet into any desired shape using a mold by applying heat and
pressure.
THERMOFORMING MACHINE PARTS & FUNCTION
Main Control Panel
The Main control panel system is a device
that regulates the Machine Operation process of each part connecting to each other.

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WORKSHOP ACTIVITY #4The Thermoforming Machine and Mold

Theoretical Background continued


Unreeling/Unwinding Station
To introduce the sheet into the Feed zone up
to Heating station, the following procedures
must be followed:

Rolled sheet must be properly inserted


into the shaft.

Using the Lever arm loader, rolled sheet


must be firmly positioned in the unwinding stand and the exact tension should
be applied.

Heating Station
Thermoplastic sheet is heated and softened
in this station. The guidelines for heating the
sheet are the following:

Temperature should be properly controlled to prevent excessive sag.

Forming Station
In this station, the thermoplastic sheet is
formed into its desired shape, with the required thermoforming process.
Parts of Forming Station:

Clamping Framesused to guide and


hold the sheet during machine operation.

Tool (Mold)a devise used to form the


plastic sheet into the desired shape.

Plug-assistA mechanical device used


in thermoforming to help distribute the
heated plastic sheet more uniformly before it actually seats on the mold.
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WORKSHOP ACTIVITY #4The Thermoforming Machine and Mold

Theoretical Background continued


Cutting Station
In this station, the molded products are cut
and separated from the sheet/runner.
Parts of Cutting Station:

Knife Corealuminum block that supports the knife.

Cutting Knifesharp edged metal part


used to cut and separate the formed
products from the sheet .

Stacking Station
In this station, the finished products are collected to the desired amount using the
pusher.
Parts of Stacking Station:

Stacking Cagepart of stacking station


where molded parts are collected and
stacked at the desired quantity.

Pusherused to put the molded parts


into the stacking cage.

Ejector Platea plate located on top of


the stacking station used to push the
products on top of the conveyor.

Winding Station
In this station, the runner is rolled or collected. Skeleton sheet or runner should be
properly positioned at the winding roller.

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WORKSHOP ACTIVITY #4The Thermoforming Machine and Mold

Theoretical Background continued


THERMOFORMING MOLDS
Thermoforming mold is a device used to form the plastic sheet into the
desired shape. There are two types of thermoforming molds:

Prototype (Low Volume Production), and

Aluminum (High Speed - High Production)

Prototype Mold
This is the mold that is used to make a part that will be evaluated for fit and
function. It is used for low-volume production runs.
Different Kinds of Prototype Mold

Plaster/3D PrintPlaster molds are cast directly from the model and
used for prototyping. Other casting method is by the use of special
3D printing device to form a mold that is precisely to what is needed.

WoodA wooden mold is used mainly for a customer required


prototype or a very low volume production run.

Epoxy/PolyurethaneA thermosetting plastic mold used for short


production runs that may last at 100 up to 300 parts (shots).

Aluminum Mold
This is a kind of mold made of cast (or machine) aluminum that is prepared
by casting or by layering. Their surfaces can be textured or polished to a
high gloss. Aluminum is an excellent heat conductor and permits rapid
heating and cooling for fast cycles.
Different Kinds of Aluminum Mold

Porous AluminumAn aluminum material used for products that


require high optical quality or other cosmetic applications.

Cast AluminumCast aluminum material is commonly used for thin


gauge applications and having difficult shapes.

Solid AluminumDedicated for technical/engineered trays.

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WORKSHOP ACTIVITY #4The Thermoforming Machine and Mold

Theoretical Background continued


TWO TYPES OF MOLD DESIGNS

Male MoldA male mold or convex mold that has one or more
protrusions over which the heated sheet is drawn to form a shape.

Female MoldFemale mold or concave mold that has one or more


cavities into which the heated sheet is drawn to form a shape.

THREE (3) KINDS OF MOLD COOLING SYSTEMS

Ambient Air / Air Spraymost commonly used in vacuum forming


applications.

In-direct Coolingthe cooling is done thru a cooling block.

Direct Coolingmold with integrated cooling channels.

Mold Cooling Table


Type of production
Prototypes max 100 trays
Medium production 100 to 5000str/m

Ambient air, air


spray

Indirect cooling

Direct cooling

Al tool

With PU tool

PU, Plaster, wood

High vol. Production >5000 str/m

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WORKSHOP ACTIVITY #4The Thermoforming Machine and Mold

Theoretical Background continued


VENTING/VACUUM HOLES
Vacuum holes are mold features where the negative air (vacuum air) is
allowed to pass upon forcing the softened plastic sheet against the mold.

Standard Drilled Holes Dimension:


0.3mm, 0.5mm, 3mm, 5mm

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WORKSHOP ACTIVITY #4The Thermoforming Machine and Mold

OBJECTIVES OF THE ACTIVITY


1. To be able to know the different kinds of thermoforming machines, the
parts and function of an ILLIG thermoforming machine and their
specifications.
2. To be able to learn the importance of thermoforming mold, its parts and
the different methods applied.
3. To have a total knowledge about mold assembly and mold parts.

PROCEDURE
Part IThe Basic Parts of Thermoforming Machine
1. Go to the machine site and try to know the different parts of the
Thermoforming Machine.
2. Observe the motion of the different moving parts of the machine and how
the plastics products are formed.
3. In your data sheet, give the names of the parts that are shown on the page
and explain the functions of each of the parts.
Part IIThermoforming Mold
1. Familiarize yourself with the different mold materials used for
thermoforming mold and try to identify the parts and methods applied in
the mold.
2. In your data sheet, match the word that identify each category or word
that related to each other and to its application

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DATA S H E E T
ACTIVITY #4The Thermoforming Machine and Mold
TRAINEE NAME

GROUP NO.

Part IThe Basic Parts of Thermoforming Machine


1.

Part:
Function:

2.

Part:
Function:

3.

Part:
Function:

4.

Part:
Function:

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DATA S H E E T
ACTIVITY #4The Thermoforming Machine and Mold
TRAINEE NAME

GROUP NO.

Part IThe Basic Parts of Thermoforming Machine continued


5.

Part:
Function:

6.

Part:
Function:

7.

Part:
Function:

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DATA S H E E T
ACTIVITY #4The Thermoforming Machine and Mold
TRAINEE NAME

GROUP NO.

Part IIThermoforming Mold


TYPES OF THERMOFORMING MOLDS
1. Low volume production mold
2. Prototype mold made of wood
3. High volume production mold
4. Thermosetting plastic mold
5. Mold that has convex surface
6. Mold used for technical trays
7. Mold that has concave surface
8. Mold for high optical quality product
Answer: (Pick the Answer and Match the word)
Porous Aluminum Mold, Male Mold, Aluminum Mold, Prototype Mold,
Female Mold, Solid Aluminum Mold, Epoxy/Polyurethane Mold, Wooden
Mold.
MOLDS COOLING SYSTEM
1. Cooling thru cooling block
2. Mold w/ integrated cooling channels
3. Ambient air / air spray
4. Vacuum holes
Answer: (Pick the Answer and Match the word)
In-direct cooling, Drilled holes under the mold, Direct cooling, Vacuum
forming conventional cooling
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WORKSHOP ACTIVITY #4The Thermoforming Machine and Mold

QUESTIONS & EXERCISES


Choose the correct answer.
1.

____________ is a device having parts that perform or assist in


performing any type of work. Devices with no rigid moving parts can
be considered as tools.
a. Machine
b. Mold
c. Method
d. Material

2.

____________is a device used to make or transform a thermoplastic


sheet into any desired shape using a mold by applying heat and
pressure.
a. Recycling machine
b. Sheet extrusion machine
c. Thermoforming machine
d. Injection molding machine

3.

Maximum cycle rate of Illig RV53b thermoforming machine is


____________ cycles per minute.
a. 20
b. 22
c. 24
d. 42

4.

What are the main functions of the thermoforming mold?


a. Receive and distribute the material to the surface of the mold
b. Cool the material after forming (water or oil as coolant)
c. Eject the molded product out of the mold
d. All of the above

5.

This is a device used to form the plastic sheet into its desired shape.
a. Mold
b. Plug-Assist
c. Knife
d. Pressure

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WORKSHOP ACTIVITY #4The Thermoforming Machine and Mold

QUESTIONS & EXERCISES continued


6. Identify the thermoforming machine work station shown in the picture.
a. Winding station
b. Unreeling station
c. Heating station
d. Forming station

7. Identify the thermoforming machine work station shown in the picture.


a. Winding station
b. Heating station
c. Unreeling station
d. Forming station

8. Identify the thermoforming machine work station shown in the picture.


a. Forming station
b. Unreeling station
c. Heating station
d. Winding station

9. Identify the thermoforming machine part shown in the picture.


a. Plug Assist
b. Thermoforming Mold
c. Clamping frames
d. Knife-core Assembly

10. Identify the thermoforming machine part shown in the picture.


a. Mold
b. Clamping Frame
c. Plug-Assist
d. Knife-core Assembly

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Wo r k b o o k fo r T h e r m o fo r m i n g P ra c t i c a l C o u r s e
WORKSHOP ACTIVITY #4The Thermoforming Machine and Mold

CONCLUSION & RECOMMENDATIONS

___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
________________________
DATE: __________________

TRAINEES SIGNATURE

INSTRUCTORS COMMENTS

TRAINEES GRADE
FOR THIS ACTIVITY

________________________
DATE: __________________

INSTRUCTORS SIGNATURE
Page 52

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WORKSHOP ACTIVITY #5

Thermoforming Methods & Processes


THEORETICAL BACKGROUND
Thermoforming is a simple process: a sheet of thermoplastic is heated and
formed into a designed shape by applying heat and pressure. The sheet is
stretched into a larger shape, which reduces the sheets original thickness and
results in a bigger surface area.
THERMOFORMING METHODS & PROCESSES
1. Vacuum Forming Method
Vacuum forming is a process that involves forming thermoplastic sheets into
three-dimensional shapes through the application of heat and pressure.
Advantages:
Economical for small to medium production runs
Low tooling costs
Quick startup
High strength to weight ratio
Efficient prototyping
No need for painting; the color and texture are formed in.
Vacuum Forming Schematic Diagram

Heater

Formed Product

Heated Sheet

Female Mold

Vacuum Air

Page 53

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WORKSHOP ACTIVITY #5Thermoforming Methods & Processes

Theoretical Background continued


2. Pressure Forming Method
A thermoforming technique whereby vacuum and pressure is used to force
the hot plastic sheet against a mold surface to get a very crisp impression of
that surface.
Pressure Forming Schematic Diagram
Pressure Box

Pressure Box

Heated Sheet

Pressurized Air

Mold

Vacuum Air

3. Plug Assist Forming Method


This is basically the same as straight vacuum forming. But, the heated and
softened sheet is pressed down into the mold by a plug.
After the plug reaches a predefined depth, a vacuum is created inside the
mold so that the sheet is drawn down and forms the shape of the container.
Advantages:
Economical for small to medium production runs
Low tooling costs
Quick startup
High strength to weight ratio
Efficient prototyping
No need for painting; the color and texture are formed in.

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WORKSHOP ACTIVITY #5Thermoforming Methods & Processes

Theoretical Background continued


Plug Assist Forming Schematic Diagram
Plug Assist
Heated
Sheet

Mold

Vent

4. Other Thermoforming Processes

Straight Vacuum Thermoforming

Drape Thermoforming

Free Draw Thermoforming

Matched-Mold Thermoforming

Snap-back Thermoforming

Billow Forming

Twin-Sheet Forming

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WORKSHOP ACTIVITY #5Thermoforming Methods & Processes

OBJECTIVES OF THE ACTIVITY


1. To give trainees an in-depth knowledge on the three (3) kinds of
thermoforming processes, and the advantages and disadvantages of each
method.
2. To give trainees an introduction to all the processes of an ILLIG RV 53b
thermoforming machine.

PROCEDURE
Part IThermoforming Methods/Processes
1. Go to the machine site and try to observe the process that is being used to
get a good product.
2. In your data sheet, explain each given Thermoforming process and draw
a simple schematic diagram of each.
Part IIThermoforming Machine (ILLIG RV53b) Processes
1. Familiarize yourself with the thermoforming processes of an ILLIG
RV53b thermoforming machine.
2. In your data sheet, explain the whole process of the basic Thermoforming
Machine (iLLig RV53b) and its methods of process.

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DATA S H E E T
ACTIVITY #5Thermoforming Methods & Processes
TRAINEE NAME

GROUP NO.

Part IThermoforming Methods/Processes


1. Vacuum Forming Process
Explain the process:
_______________________________________________________________________
_______________________________________________________________________
________________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________

Draw the schematic diagram.

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DATA S H E E T
ACTIVITY #5Thermoforming Methods & Processes
TRAINEE NAME

GROUP NO.

Part IThermoforming Methods/Processes continued


2. Pressure Forming Process
Explain the process:
_______________________________________________________________________
_______________________________________________________________________
________________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________

Draw the schematic diagram.

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DATA S H E E T
ACTIVITY #5Thermoforming Methods & Processes
TRAINEE NAME

GROUP NO.

Part IThermoforming Methods/Processes continued


3. Plug-Assist Forming Process
Explain the process:
_______________________________________________________________________
_______________________________________________________________________
________________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________

Draw the schematic diagram.

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DATA S H E E T
ACTIVITY #5Thermoforming Methods & Processes
TRAINEE NAME

GROUP NO.

Part IIThermoforming Machine (ILLIG RV53b) Processes

Explain each process:


Station 1

Station 2

Station 3

Station 4

Station 5

Station 6

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WORKSHOP ACTIVITY #5Thermoforming Methods & Processes

QUESTIONS & EXERCISES


Choose the correct answer.
1. Heating is done by top and bottom infrared ceramic heaters with built in
thermocouple. Heating allows sheet to ____________ without any
physical contact.
a. melt

b. soften

c. burn

d. crush

2. Upon switching the machine on, the screen page ____________ appears
on the display screen of control panel.
a. main menu b. temperature menu c. production menu d. clear menu
3. In automatic mode the cutting and stacking station ____________ after
starting production.
a. do not run

b. run

c. simultaneously run

d. intermittent run

4. We can select the operation mode by selecting the symbols in


OPERATION MODES. To run the machine in auto mode which symbol
do we need to select. (Please put tick mark on correct symbol in
following picture).

5. Forming station has ____________ mold to form the sheet into the
desired shape. This is done by application of either air and/or vacuum.
a. top and bottom

b. top

c. bottom

d. sides

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WORKSHOP ACTIVITY #5Thermoforming Methods & Processes

QUESTIONS & EXERCISES continued


6. The function of the unreeling device is to ____________ the rolled sheet
into the machine thru the feeder zone using a sensor to activate the
loading automatically.
a. unload

b. hold

c. load

d. remove

7. What process of thermoforming is being applied when heated and


softened plastic sheet from extrusion is placed at the top of a female mold
and formed by vacuum only?
a. Straight vacuum forming
b. Pressure

c. Match mold forming


d. Billow forming

8. What process of thermoforming is being applied when heated and


softened plastics sheet is placed at top of a female mold and formed by
pressure and vacuum?
a. Straight vacuum forming
c. Thermoforming
b. Pressure forming
d. Billow forming
9. What process of thermoforming is being applied when heated and
softened plastics sheet is placed at the top of a female mold and formed
and pressed by plug and with application of vacuum?
a. Plug-assist forming

c. Billow forming

b. Pressure forming

d. Vacuum forming

10. Forming station has ____________ mold to form the sheet into the
desired shape. This is done by application of either air and/or vacuum.
a. top and bottom

b. top

c. bottom

d. sides

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Wo r k b o o k fo r T h e r m o fo r m i n g P ra c t i c a l C o u r s e
WORKSHOP ACTIVITY #5Thermoforming Methods & Processes

CONCLUSION & RECOMMENDATIONS

___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
________________________
DATE: __________________

TRAINEES SIGNATURE

INSTRUCTORS COMMENTS

TRAINEES GRADE
FOR THIS ACTIVITY

________________________
DATE: __________________

INSTRUCTORS SIGNATURE
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WORKSHOP ACTIVITY #6

Manpower and Standard Operating Procedures


THEORETICAL BACKGROUND
Take note that Standard Operating Procedures and Policies can be effective
catalysts to drive performance improvement and improving the desired
results.
Manpower is either an abstract term for human labor effort (as opposed to
machines, animals etc.) or the number of available/needed for professional
or other tasks.
In plastic fabrication, manpower is referred to as the operator of the machine.
Included in the manpower lists are anybody (overhead) from the supervisory
level up to the highest position working in the company.
Standard Operating Procedure
for iLLiG RV 53b Thermoforming Machine
OPERATORS ROLE:
1. Step by step approach on how to operate the RV 53b Thermoforming
machine and its auxiliaries from start-up to shutting down operation
including safety, product quality (checking procedures).
2. How to apply 3 S in the Standard Operating Procedures.
Summary of SOP are the following :
1.0

2.0
3.0
4.0
5.0

Observe the Safety signs


1.1
Important Safety Reminders
1.2
Additional Important Reminder
Switch on the air compressor.
Switch on the water chiller as shown and set the recommended water
temperature (normally at 10C)
Open the main air and water supply line by turning on valve.
General Machine check-up

Page 64

Wo r k b o o k fo r T h e r m o fo r m i n g P ra c t i c a l C o u r s e
WORKSHOP ACTIVITY #6Manpower and Standard Operating Procedures

Theoretical Background continued


6.0

When checklist has been complied and everything have been fulfilled, switch on the main power supply and the light switch on.

7.0

To ensure absolute safety, the lead Operator must double check.

8.0

Machine Switching-on Procedure

9.0

Overview of Control Panel Screen

10.0

Follow the procedure to star the machine and run the machine.

11.0

Doing quality checks and production segregation.

12.0

Follow the procedure to shut down the machine.

13.0

Do the last S.

14.0

Reporting system

Following is the example of how SOP explains the parts, Functions and the
detail pictures and video procedures for operating individual part of each
work station. (Note: - For detail SOP please refer the Hand outs of day 6.)
Sample of SOP: 1

Push the main heater button switch.

Page 65

Wo r k b o o k fo r T h e r m o fo r m i n g P ra c t i c a l C o u r s e
WORKSHOP ACTIVITY #6Manpower and Standard Operating Procedures

Theoretical Background continued


Sample of SOP: 2
FUNCTIONThe function of the Unreeling Device is to load the rolled
sheet into the machine thru the feeder zone using a sensor to activate the
loading automatically.
7

6
4
5

1. Control panelused to activate the loading/unloading of rolled sheet


materials
2. Tension adjusterused to regulate the movement of the loaded rolled
sheet
3. Lever arm loaderused to load/unload rolled sheet using the control
panel
4. Shaft for roll sheetsused to hold and unwind the rolled sheet
5. Pneumatic cylinder of lever armused to activate movement of the lever
arm loader
6. Sheet feed rollerused to guide the sheet into the feeder zone
7. Feeder zoneused to guide the sheet into the chain conveyor

Page 66

Wo r k b o o k fo r T h e r m o fo r m i n g P ra c t i c a l C o u r s e
WORKSHOP ACTIVITY #6Manpower and Standard Operating Procedures

Theoretical Background continued


Sample of SOP: 3Reporting:
Production Data:
Cycles per minuteis determined from the cycle time.
Cycle timeTime required for one cycle.
Sheet unwind to the forming machineLength of the sheet web in mm up to
behind the forming station, if a roller preheater or unwind device is used.
Production cyclesQuantity of cycles run in the current operation program.
Production timeTime required for production.
Reading Production Data From Control Panel

Page 67

Wo r k b o o k fo r T h e r m o fo r m i n g P ra c t i c a l C o u r s e
WORKSHOP ACTIVITY #6Manpower and Standard Operating Procedures

OBJECTIVES OF THE ACTIVITY


1. To learn the importance of manpower in the plastics industry, specially
the role of an Machine Operator
2. To understand the importance of the Standard Operating Procedure and
its application in machine operations

PROCEDURE
Part I - Thermoforming Methods/Processes
1. Proceed to the Machine site and follow the Standard Operating Procedure
(Machine Start-up and Machine Shutdown) in operating the
Thermoforming machine.
2. Put a check in the box in your data sheet to indicate that you have
properly done the step.

SOP for Machine Startup


1.

Follow Safety Instructions.

2.

Switch on the air compressor.

3.

Switch on the water chiller and set the recommended water


temperature (normally at 10C).

4.

Open the main air and water supply line by turning ON valve.

5.

Do General Machine Check-up.

6.

When checklist has been complied and everything have been


fulfilled, switch on the main power supply and the light switch.

7.

To ensure absolute safety, the lead Operator must double


check.

8.

Do Machine Cycle/Production Procedure.

9.

Do quality checks and production segregation.


Page 68

Wo r k b o o k fo r T h e r m o fo r m i n g P ra c t i c a l C o u r s e
WORKSHOP ACTIVITY #6Manpower and Standard Operating Procedures

Procedure continued

SOP for Machine Shutdown


1.

Push the button to turn-off machine cycle.

2.

Push the button to turn off the heating.

3.

Check the machine and take-out the products/ skeleton/


runner inside of the machine.

4.

Push button to turn-off the control voltage.

5.

Check the temperature. When the heating temperature decreases and reached 300C, switch off the chiller.

6.

Switch off the main power of Thermoforming machine.

7.

Switch off the compressor.

8.

Do the 5S.

9.

Follow the reporting system.

Page 69

Report Form - Page 1 of 4

Cut Report Form and Submit to Instructor

DATA S H E E T
ACTIVITY #6Manpower and Standard Operating Procedures
TRAINEE NAME

GROUP NO.

Standard Operating Procedure


1. Machine Startup
Steps
1.

Check

Follow Safety Instructions.

Important Safety Reminders

Additional Safety Reminders


(Advise by Instructors)

2.

Switch on the air compressor.

3.

Switch on the water chiller and set the recommended


water temperature (normally at 10C).

4.

Open the main air and water supply line by turning


ON valve.

5.

Do General Machine Check-up.

6.

When checklist has been complied and everything


have been fulfilled, switch on the main power supply
and the light switch.

7.

To ensure absolute safety, the lead Operator must


double check.

8.

Do Machine Cycle/Production Procedure.

9.

Do quality checks and production segregation.

Page 70

Report Form - Page 2 of 4

Cut Report Form and Submit to Instructor

DATA S H E E T
ACTIVITY #6Manpower and Standard Operating Procedures
TRAINEE NAME

GROUP NO.

Standard Operating Procedure


2. Machine Shutdown
Steps
1.

Push the button to turn-off machine cycle.

2.

Push the button to turn off the heating.

3.

Check the machine and take-out the products/ skeleton/ runner inside of the machine.

4.

Push button to turn-off the control voltage.

5.

Check the temperature. When the heating temperature decreases and reached 300C, switch off the
chiller.

6.

Switch off the main power of Thermoforming machine.

7.

Switch off the compressor.

8.

Do the 5S.

9.

Follow the reporting system.

Check

Page 71

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Wo r k b o o k fo r T h e r m o fo r m i n g P ra c t i c a l C o u r s e
WORKSHOP ACTIVITY #6Manpower and Standard Operating Procedures

QUESTIONS & EXERCISES


Choose the correct answer.
1. Actuation of ___________ is necessary if an unwanted thing happens
during machine operations.
a. Emergency Button b. Switch Button

c. Switch Valves d. Control

2. Upon switching on the machine, the screen page ____________ appears


on the display screen of control panel.
a. main menu b. temperature menu c. production menu d. clear menu
3. In automatic mode, the cutting and stacking station ____________ after
starting production.
a. do not run

b. run

c. simultaneously run

d. intermittently run

4. We can select the operation mode by selecting the symbols in


OPERATION MODES. To run the machine in auto mode, which
symbol do we need to select? (Please put tick mark on correct symbol in
following picture).

5. Forming station has ____________ mold to form the sheet into the
desired shape. This is done by application of either air and/or vacuum.
a. top and bottom

b. top

c. bottom

d. sides

Page 72

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Wo r k b o o k fo r T h e r m o fo r m i n g P ra c t i c a l C o u r s e
WORKSHOP ACTIVITY #6Manpower and Standard Operating Procedures

CONCLUSION & RECOMMENDATIONS

___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
________________________
DATE: __________________

TRAINEES SIGNATURE

INSTRUCTORS COMMENTS

TRAINEES GRADE
FOR THIS ACTIVITY

________________________
DATE: __________________

INSTRUCTORS SIGNATURE
Page 73

Wo r k b o o k fo r T h e r m o fo r m i n g P ra c t i c a l C o u r s e

WORKSHOP ACTIVITY #7

Product Quality, Defects and Troubleshooting


THEORETICAL BACKGROUND
Quality is defined in everyday life and in business, engineering and
manufacturing as the non-inferiority, superiority or usefulness of plastic
products.
As an operator, you must always know the different defects and their impact
on quality of the products from the users point of view.
You must know how to overcome and fix the various problems during
production by making use of process parameters.
The meaning of quality has developed over time with various interpretations
below:
1. ISO 9000"Degree to which a set of inherent characteristic fulfills
requirements"
2. Six Sigma"Uniformity around a target value"
3. Philip B. Crosby"Conformance to requirements". Crosby treats
customer expectations as a separate problem.
4. Genichi TaguchiTaguchi's definition of quality is based on a more
comprehensive view of the production system: Quality as "The loss a
product imposes on society after it is shipped".
Different Quality Concepts
Many different techniques and concepts have evolved to improve product or
service quality, namely; SPC, Zero Defects, Six Sigma, Quality Circles,
TQM, Quality Management Systems (ISO 9000 & others) and
Continuous Improvement.
The quality of a product or service refers to the perception of the degree to
which the product or service meets the customer's expectations.

Page 74

Wo r k b o o k fo r T h e r m o fo r m i n g P ra c t i c a l C o u r s e
WORKSHOP ACTIVITY #7Product Quality, Defects and Troubleshooting

Theoretical Background continued


Quality Drives Productivity
Quality has no specific meaning unless related to a specific function and/or
object. Quality is a perceptual, conditional and somewhat subjective attribute.
In plastic fabrication industry, it is commonly stated that Quality drives productivity. Inspection, which is what Quality Assurance usually means, is
historical, since the work is done.
The best way to think about quality is in process control. If the process is
under control, inspection is not necessary.
Factors Influencing Product Quality
Processing Parameters
1.
2.
3.
4.

Time
Temperature
Pressure
Speed

Processing Components

Raw Material Quality


Sheet Quality

Environmental Factors
Climatic conditionsAny change in climatic conditions can change the
process and, accordingly, the quality of the product changes.

Page 75

Wo r k b o o k fo r T h e r m o fo r m i n g P ra c t i c a l C o u r s e
WORKSHOP ACTIVITY #7Product Quality, Defects and Troubleshooting

Theoretical Background continued


Achieving Quality
To achieve good quality in the end product, the sheet thickness, the layer
thickness and the surface area of sheet must be of good quality.
All service conditions and the majority of end use applications involve some
degree of mechanical loading.
In general, thermoforming is possible with the sheet ranging in thickness
from 0.5 to 15 mm.
TROUBLESHOOTING
Troubleshooting is not an exact science and often involves juggling a dozen
or more variables in a single sheet. The best way to look at and solve these
components are in three stages, namely:
1. The "Symptom": What is it that you see, feel, or measure? What is the
viewed problem with the formed part?
2. The "Root Cause" or "Disease" Issue: There may be a number of these
that could cause a similar "symptom."
3. The "Cure": What are the options that we have to get at the root cause
of the problem?

Page 76

Wo r k b o o k fo r T h e r m o fo r m i n g P ra c t i c a l C o u r s e
WORKSHOP ACTIVITY #7Product Quality, Defects and Troubleshooting

Theoretical Background continued


Common Forming Defects

Uneven wall thickness

Wrinkles

Warped parts

Incomplete forming of parts

Poor surface finish

Blushing or loss of color

Chill marks or mark-off

Nipple on mold side of formed part

Poor wall thickness distribution and excessive thinking in some


areas

Shrink marks

Voids or bubbles in formed parts

Tearing of sheet during forming

Crazed or brittle parts

SUMMARY
The most progressive view of quality is that it is defined entirely by the customer or end user and is based upon that person's evaluation of the entire
customer experience.

Page 77

Wo r k b o o k fo r T h e r m o fo r m i n g P ra c t i c a l C o u r s e
WORKSHOP ACTIVITY #7Product Quality, Defects and Troubleshooting

OBJECTIVES OF THE ACTIVITY


1. To learn the basics of Quality checking and its importance to the
production.
2. To identify different kinds of product defects and perform
troubleshooting.

PROCEDURE
1. Operate the RV53b Thermoforming Machine and collect product
samples.
2. Segregate the good products and the rejected (bad) products.
3. Identify the kind of defect that the rejected (bad) products have.
4. Suggest a solution to eliminate the defects and do troubleshooting.
5. In your data sheet, write down the defects and explain what solution/s
were made to correct the problem.

Page 78

Report Form - Page 1 of 4

Cut Report Form and Submit to Instructor

DATA S H E E T
ACTIVITY #7Product Quality, Defects and Troubleshooting
TRAINEE NAME

GROUP NO.

Description of Defects
Found on Products

Troubleshooting:
What did you do
to correct the problem?

__________________________________

__________________________________

__________________________________

__________________________________

__________________________________

__________________________________

__________________________________

__________________________________

__________________________________

__________________________________

__________________________________

__________________________________

__________________________________

__________________________________

__________________________________

__________________________________

__________________________________

__________________________________

__________________________________

__________________________________

__________________________________

__________________________________

__________________________________

__________________________________

__________________________________

__________________________________

__________________________________

__________________________________

__________________________________

__________________________________

__________________________________

__________________________________

__________________________________

__________________________________

__________________________________

__________________________________

__________________________________

__________________________________

__________________________________

__________________________________

Page 79

Report Form - Page 2 of 4

Cut Report Form and Submit to Instructor

Wo r k b o o k fo r T h e r m o fo r m i n g P ra c t i c a l C o u r s e
WORKSHOP ACTIVITY #7Product Quality, Defects and Troubleshooting

QUESTIONS & EXERCISES


1. _________ is a degree to which a set of inherent characteristic fulfills
requirements.
a. ISO 9000
b. Quality Form
c. Quality Data
d. Fishbone Diagram
2. ___________ is one of the 4 factors that influence product quality.
a. Temperature
b. People
c. Animals
d. Food
3. ___________ is the process of recovering scrap or waste plastics
products and reprocessing it again.
a. Recycling
b. Cycling
c. Production
d. Troubleshooting
4. When we get marks at the bottom of the thermoformed part, we need to
increase the dimensions / numbers of ____________ holes.
a. venting / vacuum
b. cooling holes
c. tube pipe
d. PVC pipe
5. When the sheet is overheated, operator must reduce the heater
temperature and decrease ________ time.
a. cycle
b. cutting
c. speed
d. clearance

Page 80

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Wo r k b o o k fo r T h e r m o fo r m i n g P ra c t i c a l C o u r s e
WORKSHOP ACTIVITY #7Product Quality, Defects and Troubleshooting

QUESTIONS & EXERCISES continued


6. If pressure and/or vacuum timing is not optimized, then we get very good
parts.
a. True
b. False
7. Sagging of material (when material touches the mold) results in folds on
thermoformed part.
a. True
b. False
8. Besides traditional applications and the use of pressure forming method,
thermoforming has conquered an important market share in the
packaging industry.
a. True
b. False
9. Choose three (3) factors influencing product quality.
a. Processing Parameters
b. Processing Components
c. Manpower
d. Environmental Factors
e. Machine Capacity
f. Environmental Factors
10. Choose two (2) processing components.
a. Raw Material Quality
b. Temperature
c. Manpower
d. Pressure
e. Sheet Quality
f. Management
g. Machine

Page 81

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Wo r k b o o k fo r T h e r m o fo r m i n g P ra c t i c a l C o u r s e
WORKSHOP ACTIVITY #7Product Quality, Defects and Troubleshooting

CONCLUSION & RECOMMENDATIONS

___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
________________________
DATE: __________________

TRAINEES SIGNATURE

INSTRUCTORS COMMENTS

TRAINEES GRADE
FOR THIS ACTIVITY

________________________
DATE: __________________

INSTRUCTORS SIGNATURE
Page 82

Wo r k b o o k fo r T h e r m o fo r m i n g P ra c t i c a l C o u r s e

WORKSHOP ACTIVITY #8

Hands-on and Practical Training (1)


THEORETICAL BACKGROUND
After successfully completing all the topics from session 1-7, it is now time
to apply all the principles, theories and actual machine practices that you
have learned so that you will develop your skills (machine operation
proficiency). However, since we have only one machine, you will be divided
into 8 groups at 4-5 trainees per group.
You are advised to review from time all the hand outs given to you aside
from the classroom review class to be conducted by your Senior and Junior
Instructions while you are waiting for your turn to operate the machine.
You will also be taught on how to fill up the machine parameters, production
report and activity report forms.

PRACTICE YOUR OPERATIONS SKILLS!


1.

2.
3.
4.

5.
6.

Now that you have learned the basics of the thermoforming process, it
is time to practice your skills in running the plant and producing
acceptable products.
Strictly follow the Standard Operating Procedures (SOP) for each plant
operations that you are going to perform.
Use the worksheet tables and forms in the next pages to record your
data.
After each practice operations, write your general comment on the how
well you have done your practice in the Conclusion &
Recommendations page.
Write down what you have done well, and what you should improve
for the next practice.
Enjoy practicing while being safe!

Page 83

Wo r k b o o k fo r T h e r m o fo r m i n g P ra c t i c a l C o u r s e
WORKSHOP ACTIVITY #8Hands-on and Practical Training (1)

STANDARD OPERATING PROCEDURES

SOP for Machine Startup


1.

Follow Safety Instructions.

2.

Switch on the air compressor.

3.

Switch on the water chiller and set the recommended water temperature (normally at 10C).

4.

Open the main air and water supply line by turning ON valve.

5.

Do General Machine Check-up.

6.

When checklist has been complied and everything have been fulfilled, switch on the main power supply and the light switch.

7.

To ensure absolute safety, the lead Operator must double check.

8.

Do Machine Cycle/Production Procedure.

9.

Do quality checks and production segregation.

SOP for Machine Shutdown


1.

Push the button to turn-off machine cycle.

2.

Push the button to turn off the heating.

3.

Check the machine and take-out the products/ skeleton/runner inside of the machine.

4.

Push button to turn-off the control voltage.

5.

Check the temperature. When the heating temperature decreases


and reached 300C, switch off the chiller.

6.

Switch off the main power of Thermoforming machine.

7.

Switch off the compressor.

8.

Do the 5S.

9.

Follow the reporting system.

Page 84

Report Form - Page 1 of 4

Cut Report Form and Submit to Instructor

DATA S H E E T
ACTIVITY #8Hands-on and Practical Training (1)
TRAINEE NAME

GROUP NO.

MACHINE PARAMETER FORM

Illig Thermoforming Machine


RV 53b
Parameter Setting Record

Prepared by :

Checked by :
Thermoforming Senior Instructors

Page 85

Report Form - Page 2 of 4

Cut Report Form and Submit to Instructor

DATA S H E E T
ACTIVITY #8Hands-on and Practical Training (1)
TRAINEE NAME

GROUP NO.

PRODUCTION REPORT FORM

Illig Thermoforming Machine


RV 53b
Production Report

Prepared by :

Checked by :
Thermoforming Senior Instructors

Page 86

Report Form - Page 3 of 4

Cut Report Form and Submit to Instructor

DATA S H E E T
ACTIVITY #8Hands-on and Practical Training (1)
TRAINEE NAME

GROUP NO.

ACTIVITY REPORT FORM

Illig Thermoforming Machine


RV 53b
Date:

Time:

Prepared by :

Checked by :
Thermoforming Senior Instructors

Page 87

Report Form - Page 4 of 4

Cut Report Form and Submit to Instructor

Wo r k b o o k fo r T h e r m o fo r m i n g P ra c t i c a l C o u r s e
WORKSHOP ACTIVITY #8Hands-on and Practical Training (1)

CONCLUSION & RECOMMENDATIONS

___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
________________________
DATE: __________________

TRAINEES SIGNATURE

INSTRUCTORS COMMENTS

TRAINEES GRADE
FOR THIS ACTIVITY

________________________
DATE: __________________

INSTRUCTORS SIGNATURE
Page 88

Wo r k b o o k fo r T h e r m o fo r m i n g P ra c t i c a l C o u r s e

WORKSHOP ACTIVITY #9

Hands-on and Practical Training (2)


THEORETICAL BACKGROUND
After successfully completing all the topics from session 1-7, it is now time
to apply all the principles, theories and actual machine practices that you
have learned so that you will develop your skills (machine operation
proficiency). However, since we have only one machine, you will be divided
into 8 groups at 4-5 trainees per group.
You are advised to review from time all the hand outs given to you aside
from the classroom review class to be conducted by your Senior and Junior
Instructions while you are waiting for your turn to operate the machine.
You will also be taught on how to fill up the machine parameters, production
report and activity report forms.

PRACTICE YOUR OPERATIONS SKILLS!


1.

2.
3.
4.

5.
6.

Now that you have learned the basics of the thermoforming process, it
is time to practice your skills in running the plant and producing
acceptable products.
Strictly follow the Standard Operating Procedures (SOP) for each plant
operations that you are going to perform.
Use the worksheet tables and forms in the next pages to record your
data.
After each practice operations, write your general comment on the how
well you have done your practice in the Conclusion &
Recommendations page.
Write down what you have done well, and what you should improve
for the next practice.
Enjoy practicing while being safe!

Page 89

Wo r k b o o k fo r T h e r m o fo r m i n g P ra c t i c a l C o u r s e
WORKSHOP ACTIVITY #9Hands-on and Practical Training (2)

STANDARD OPERATING PROCEDURES

SOP for Machine Startup


1.

Follow Safety Instructions.

2.

Switch on the air compressor.

3.

Switch on the water chiller and set the recommended water temperature (normally at 10C).

4.

Open the main air and water supply line by turning ON valve.

5.

Do General Machine Check-up.

6.

When checklist has been complied and everything have been fulfilled, switch on the main power supply and the light switch.

7.

To ensure absolute safety, the lead Operator must double check.

8.

Do Machine Cycle/Production Procedure.

9.

Do quality checks and production segregation.

SOP for Machine Shutdown


1.

Push the button to turn-off machine cycle.

2.

Push the button to turn off the heating.

3.

Check the machine and take-out the products/ skeleton/runner inside of the machine.

4.

Push button to turn-off the control voltage.

5.

Check the temperature. When the heating temperature decreases


and reached 300C, switch off the chiller.

6.

Switch off the main power of Thermoforming machine.

7.

Switch off the compressor.

8.

Do the 5S.

9.

Follow the reporting system.

Page 90

Report Form - Page 1 of 4

Cut Report Form and Submit to Instructor

DATA S H E E T
ACTIVITY #9Hands-on and Practical Training (2)
TRAINEE NAME

GROUP NO.

MACHINE PARAMETER FORM

Illig Thermoforming Machine


RV 53b
Parameter Setting Record

Prepared by :

Checked by :
Thermoforming Senior Instructors

Page 91

Report Form - Page 2 of 4

Cut Report Form and Submit to Instructor

DATA S H E E T
ACTIVITY #9Hands-on and Practical Training (2)
TRAINEE NAME

GROUP NO.

PRODUCTION REPORT FORM

Illig Thermoforming Machine


RV 53b
Production Report

Prepared by :

Checked by :
Thermoforming Senior Instructors

Page 92

Report Form - Page 3 of 4

Cut Report Form and Submit to Instructor

DATA S H E E T
ACTIVITY #9Hands-on and Practical Training (2)
TRAINEE NAME

GROUP NO.

ACTIVITY REPORT FORM

Illig Thermoforming Machine


RV 53b
Date:

Time:

Prepared by :

Checked by :
Thermoforming Senior Instructors

Page 93

Report Form - Page 4 of 4

Cut Report Form and Submit to Instructor

Wo r k b o o k fo r T h e r m o fo r m i n g P ra c t i c a l C o u r s e
WORKSHOP ACTIVITY #9Hands-on and Practical Training (2)

CONCLUSION & RECOMMENDATIONS

___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
________________________
DATE: __________________

TRAINEES SIGNATURE

INSTRUCTORS COMMENTS

TRAINEES GRADE
FOR THIS ACTIVITY

________________________
DATE: __________________

INSTRUCTORS SIGNATURE
Page 94

Wo r k b o o k fo r T h e r m o fo r m i n g P ra c t i c a l C o u r s e

WORKSHOP ACTIVITY #10

Hands-on and Practical Training (3)


THEORETICAL BACKGROUND
After successfully completing all the topics from session 1-7, it is now time
to apply all the principles, theories and actual machine practices that you
have learned so that you will develop your skills (machine operation
proficiency). However, since we have only one machine, you will be divided
into 8 groups at 4-5 trainees per group.
You are advised to review from time all the hand outs given to you aside
from the classroom review class to be conducted by your Senior and Junior
Instructions while you are waiting for your turn to operate the machine.
You will also be taught on how to fill up the machine parameters, production
report and activity report forms.

PRACTICE YOUR OPERATIONS SKILLS!


1.

2.
3.
4.

5.
6.

Now that you have learned the basics of the thermoforming process, it
is time to practice your skills in running the plant and producing
acceptable products.
Strictly follow the Standard Operating Procedures (SOP) for each plant
operations that you are going to perform.
Use the worksheet tables and forms in the next pages to record your
data.
After each practice operations, write your general comment on the how
well you have done your practice in the Conclusion &
Recommendations page.
Write down what you have done well, and what you should improve
for the next practice.
Enjoy practicing while being safe!

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WORKSHOP ACTIVITY #10Hands-on and Practical Training (3)

STANDARD OPERATING PROCEDURES

SOP for Machine Startup


1.

Follow Safety Instructions.

2.

Switch on the air compressor.

3.

Switch on the water chiller and set the recommended water temperature (normally at 10C).

4.

Open the main air and water supply line by turning ON valve.

5.

Do General Machine Check-up.

6.

When checklist has been complied and everything have been fulfilled, switch on the main power supply and the light switch.

7.

To ensure absolute safety, the lead Operator must double check.

8.

Do Machine Cycle/Production Procedure.

9.

Do quality checks and production segregation.

SOP for Machine Shutdown


1.

Push the button to turn-off machine cycle.

2.

Push the button to turn off the heating.

3.

Check the machine and take-out the products/ skeleton/runner inside of the machine.

4.

Push button to turn-off the control voltage.

5.

Check the temperature. When the heating temperature decreases


and reached 300C, switch off the chiller.

6.

Switch off the main power of Thermoforming machine.

7.

Switch off the compressor.

8.

Do the 5S.

9.

Follow the reporting system.

Page 96

Report Form - Page 1 of 4

Cut Report Form and Submit to Instructor

DATA S H E E T
ACTIVITY #10Hands-on and Practical Training (3)
TRAINEE NAME

GROUP NO.

MACHINE PARAMETER FORM

Illig Thermoforming Machine


RV 53b
Parameter Setting Record

Prepared by :

Checked by :
Thermoforming Senior Instructors

Page 97

Report Form - Page 2 of 4

Cut Report Form and Submit to Instructor

DATA S H E E T
ACTIVITY #10Hands-on and Practical Training (3)
TRAINEE NAME

GROUP NO.

PRODUCTION REPORT FORM

Illig Thermoforming Machine


RV 53b
Production Report

Prepared by :

Checked by :
Thermoforming Senior Instructors

Page 98

Report Form - Page 3 of 4

Cut Report Form and Submit to Instructor

DATA S H E E T
ACTIVITY #10Hands-on and Practical Training (3)
TRAINEE NAME

GROUP NO.

ACTIVITY REPORT FORM

Illig Thermoforming Machine


RV 53b
Date:

Time:

Prepared by :

Checked by :
Thermoforming Senior Instructors

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Report Form - Page 4 of 4

Cut Report Form and Submit to Instructor

Wo r k b o o k fo r T h e r m o fo r m i n g P ra c t i c a l C o u r s e
WORKSHOP ACTIVITY #10Hands-on and Practical Training (3)

CONCLUSION & RECOMMENDATIONS

___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
________________________
DATE: __________________

TRAINEES SIGNATURE

INSTRUCTORS COMMENTS

TRAINEES GRADE
FOR THIS ACTIVITY

________________________
DATE: __________________

INSTRUCTORS SIGNATURE
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Glossary of Technical Terms for Thermoforming


ABS

Acrylonitrile-Butadiene-Styrene terpolymer

Absorption

Is the process of radiant energy being absorbed in the


plastic as it is being heated up.

Air convection

Heat energy transferred to a plastic via the movement


of hot air about its surface area.

Air convection oven The chamber or structure used to deliver hot air to the
surface of a plastic.
AES

A saturated olefinic rubber modified styreneacrylonitrile terpolymer generally used in outdoor


exposure applications.

Alkali

Acid-neutralizing chemical substance: a water-soluble


chemical that reacts with acids to form salts, has a pH
above 7, and turns red litmus paper blue.

Alloy

A combination of blended polymers or copolymers


that result in unique physical properties not available
in the single polymer. An example is Polyvinyl
Chloride combined with Acrylonitrile-butadienestyrene.

Amorphous polymers

Polymers devoid of orderly molecular


structures. They exhibit a broad melting range as
opposed to crystalline structures.

ASA

An acrylic rubber modified styrene-acrylonitrile


terpolymer generally used in outdoor exposure
applications.

Atmospheric pressure

The pressure that is applied to the earths


surface due to the weight of the air surrounding the
surface of the earth. At sea level it is 14.7 pounds per
square inch.

Banbury mixing

A system of mixing materials together using a pair of


contra-rotating rotors that force the materials together
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into a homogeneous blend through friction and


pressure. This is an excellent mixing system and
probably the best one available for compounding
plastic alloys.
Bank

A group of heating elements that are connected


together with a common electric circuit.

Billow

Pre-stretching a heated plastic sheet by injecting air


into a chamber that has the plastic sheet sealed over
the edges of the chamber.

Black body

A body that emits the maximum amount of radiant


energy at a given wavelength.

Black panel heaters (solar panels) Heaters with resistance wires imbedded
in a routed out ceramic fiber refractory board and
covered with a black panel quartz or glass plate.
Bleed off

The act of letting air out of a mold chamber to allow a


billow to stretch uniformly over a mold so the bubble
does not burst during the forming operation.

Blisters

A depression on the surface of a heated plastic sheet or


part caused by the rupturing of the surface of the
plastic as the trapped gases are expanding very rapidly
and escaping as the plastic is softening and allowing
the rupture.

Bridging

This is a condition whereby the plastic stretching


across a mold cavity during the forming operation
does not pull down tightly against the mold surface.

Bubble

A pre-stretched piece of plastic that is obtained by


sealing the plastic over a vacuum or pressure box and
applying a vacuum or air pressure to this box causing
it to develop a concave or convex hemisphere.

Calrod

A resistance wire packed in magnesium inside a


stainless steel tube. When sending electricity through
this wire, the tube will heat up and give off radiant and
convective energy.
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Catalytic gas heater An enclosed panel in which natural or propane gas


enters into it and is dispersed throughout the panel and
ignited. This causes the panel to give off heat through
radiant and convective energy.
Cavity mold

A female mold in which a part is drawn into it via


vacuum or pressure.

Ceramic heater

A resistance wire trapped within a ceramic shell that


will heat up when an electric current is passed through
the wire. It is very efficient at given off radiant and
convective energy.

Chain drive

A system of raising or lowering the platens on a


thermoforming machine. Chain drives can also be
used to shuttle the plastic into and out of the oven.

Chemical reactor

The vessel that is used to polymerize a monomer


through the use of heat and pressure in the presence of
a catalyst.

Chemical resistance The ability of a material to resist having its properties


changed when being exposed to a substance that could
potentially chemically attack it.
Chill marks

A wavy surface imperfection that is caused by contact


of the hot plastic to the mold surface before other parts
of the hot plastic contact it.

Clamping frame (mechanism)


A mechanical means of holding the
edges of a plastic sheet while it is being heated in an
oven. After the sheet is heated it provides a method of
sealing the plastic to the mold edge to make it possible
to draw a vacuum.
Coefficient of thermal expansion The fractional change in length of a
material in response to a change in temperature. For
plastics this value is somewhere in the range of ten to
the minus fifth, times the temperature change, times
the length or thickness of the part in inches.
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Commodity materials

Materials that generally are similar and can be


bought and sold based on current market conditions.
For instance, benzene is a commodity. What
difference does it make where or who you buy it
from?

Conduction

A method of transferring energy to a material or body


through direct contact.

Conductive plastics

Plastics that can actually conduct an electric current,


albeit very weakly and slowly, that will dissipate an
electric charge.

Contoured box snapback This is a box that has roughly the same shape
as the mold you are trying to form the plastic over. It
has calculated amounts of clearances that prevent the
plastic from being pulled into the vacuum box too
deeply so webbing and thinning do not occur.
Convection

A method of transferring energy to a material or body


via the use of fluids or air flowing about that body.

Cooling

The process of removing heat from a formed plastic


part as it is drawn onto the mold.

Cooling lines

Tubes running through a mold that carry the fluid that


either heats up or cools off the temperature of a mold
to keep it consistent.

Cooling fixture

A device that is used to hold the shape of a part after it


is removed from the mold and is cooling off. Typically
it is used to maintain dimensional stability.

Crystalline polymers Polymers that have sharp melting points.


Crystallinity

A state whereby the molecular structure of a resin


arranges itself in a symmetrical, geometrical, threedimensional pattern forming a polymer.

Cycles cycle time

A complete sequence of events that occur in making a


plastic part from the loading of the sheet to the loading
of the next sheet to make a second part. A time lapse
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between identical spots within a repeatable sequence


of events.
Depth of draw

The distance that the mold protrudes out of the mold


base or the depth the cavity extends within the mold
from the mold base surface.

Die cutting

A system of trimming plastic parts that takes a steel


rule die and applies enough pressure to cut through the
desired areas of the plastic an stopping against a
support plate. A second system is taking two
sharpened edges and sliding them past each other
through the plane of a plastic part.

Die lines

Linear grooves or depressions in the back of an


extruded sheet that parallel the machine direction of
the plastic sheet. They are usually caused by hang-ups
in the die or nicks on the die lips.

Dimple

A depression in the surface of the plastic sheet or


formed part. The dimple can be caused by a void
within the plastic sheet or moisture within the surface
of the sheet that ruptures when the sheet is heated.

Discoloration

The process of a plastic changing color through


exposure of sunlight or applying a substance to the
plastic that chemically attacks it.

Draft

The slope of the vertical edges of a mold that is used


to facilitate the removal of the part from the mold.

Drape

The process of pulling a hot piece of plastic over a


mold creating a seal along the mold edges.

Draw ratio (stretch ratio)


The ratio of the starting thickness of the plastic
sheet to the final thickness of the plastic on the formed
part. Calculating this ratio depends on the geometry of
the part.
Elongation

The amount in length a material can increase without


breaking when put under stressed tension.
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Emissivity

The ratio of radiation intensity from a surface to the


radiation intensity at the same wavelength from a
blackbody at the same temperature.

Entropy

The tendency of an energy system or organized entity


to break down.

EPDM

Ethylene Propylene Diene Monomer that is used as a


rubber impact modifier in weatherable plastics.

Epoxy resin

A thermosetting plastic used for making molds or


tooling fixtures.

Excessive moisture

The amount of water that is absorbed in the surface of


a plastic sheet or resin that will keep you from
processing it.

Female mold

A cavity used to stretch a piece of plastic over.

Fiberglass

Fine strands of glass usually encapsulated within a


resin matrix. It can be used to make molds or
structural parts.

Flammability

A measure of the extent to which a material will


support combustion.

Flow characteristics The ability of a heated plastic to pass through a die,


through an orifice, or over a mold in a smooth and
uniform way to allow you to make a sheet or formed
part.
Foam core materials Materials that have gas expanded or air occupied
structures between their solid exterior surfaces.
Expanded vinyl or polyethylenes are good examples.
Forming temperature

The temperature at which a plastic will shape


into the geometry you are attempting to attain.

Forming temperature range


The high and low points at which a
plastic will be successfully shaped with the detail and
dimensional tolerances required for an acceptable part.
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Forming technique

A regimented process of steps that allow you to form a


flat sheet into a desired shape. There are numerous
processes that will accomplish this depending on how
complex a shape you are trying to make.

Gas flame heating

A heating system that employs an open gas flame to


heat up a plastic sheet. This system gives off both,
convective and radiant heat energy.

Gas regulator

A device that controls the amount of gas that enters a


gas heating system thereby controlling the heat output.

Gels

Hard particles of resin that are similar to the plastic


matrix they are in but because of their molecular or
cross-linked nature, will not blend in with the other
plastic and will leave a tiny blip on the surface of the
plastic sheet or part. If they are large enough they will
show in the surface of the plastic part as the sheet is
thinned out to form the part.

Glass transition temperature


The temperature at which a rigid plastic
softens enough to become somewhat rubbery.
Hardness

The property of a material that determines how rigid


or resistant to denting a substance is. In rigid plastics
this is measured by a Rockwell hardness test.

Heat distortion temperature


This is the temperature at which a
plastic will begin to distort as measured with test bars
using a standard ASTM test method.
Heating oven

The device used to heat up a plastic sheet to forming


temperature. Usually this type of oven is tightly zonecontrolled to distribute heat to the desired areas.

Heating profile

The pattern of heat being applied to a plastic sheet


while it is enclosed within an oven so that the heat will
be localized within the sheet and allow certain areas to
stretch more than others during the forming process.

Heater types

These are the various types of elements that are used


to heat up plastic sheet. General types listed in this
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manual are: ceramic, solar panel, calrod, quartz,


catalytic gas, open flame gas, nichrome wire, and air
convection.
High impact polystyrene
This is a resin composed of numerous styrene
monomer molecules polymerized into long polymer
chains and dispersed with soft rubber particles
throughout the rigid polystyrene matrix.
Hot strength

The resistance of a heated plastic sheet to being


stretched into the shape of a mold.

Hydraulic

A system of putting fluids under compression to move


the platens on a thermoforming machine up and down.
Usually used in conjunction with pressure-forming to
allow maximum clamping pressure.

Hygroscopic

The characteristic within a plastic that gives it an


affinity to pick up and retain moisture.

Impact strength

The ability of a material to undergo a sudden shock


without breaking. This can be tested in plastics via a
notched izod or falling dart impact test through
standard ASTM test methods.

KORAD

An acrylic film used to hold color stability and UV


degradation when laminated to plastic sheet.

Louvers

Air or lighting vents designed into a plastic part.

Male mold

A protrusion extending out of a flat plane that is used


to form hot plastic over.

Materials

Plastic compounds used to construct useful shapes.

Material distribution

The process of stretching hot plastic over a


mold and maintaining desired thicknesses in specific
areas of the part.

Melt temperature (point)


The temperature at which a polymer changes
from a solid to a viscous liquid.
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Micro-switch

A device used to electrically stop a moving part on a


machine in the same place consistently.

Moat

A groove in a mold used to provide a good sealing


point to prevent a plastic from breaking its vacuum
bond with the mold as the plastic is shrinking during
the cooling cycle.

Mold

(v) To shape a heated plastic sheet via heat and


vacuum (pressure) into a desired geometry. (n) The
cavity or protrusion used to shape a heated plastic
sheet into a desired shape.

Mold base

The plane that a mold cavity or mold protrusion is


mounted to that is used to seal off the hot plastic sheet
during the vacuum part of the forming cycle.

Mold shrinkage

The amount that the plastic part shrinks in relation to


the actual mold size after the part is removed from the
mold and has reached ambient air temperature. This
value is usually expressed in inches per inch. The
typical shrinkage for ABS is .006 .001.

Nichrome-wire heaters
A type of heater unit that resembles a wire in a
toaster. It typically heats up to its maximum or cools
off fairly quickly.
Notch sensitive

Most plastics exhibit a tendency to crack or break


along a notch or scratch in the surface if an excessive
bending stress is applied to that surface.

Ohms per square

The resistance to an electrical charge flowing across


the same surface of a piece of plastic.

Olefins

A group of unsaturated hydrocarbons of the general


formula CnH2n. Examples are polyethylene or
polypropylene.

Orientation

The alignment of polymer chains to create stress in a


given direction. With thermoplastic materials this
condition causes the molecular structure of the plastic
to be stressed more in one direction than the other.
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Percentage timer

A timing device that has a total amount of set time,


say 15 seconds as 100%. This timer can then be set at
a certain percent, such as 50%, in which case it would
be allowing a current to flow through a heating
element for 7.5 seconds and not allowing it to flow for
7.5 seconds.

PETG

A clear, amorphous, glycol-modified polyester which


is polymerized from dimethyl ester or terephthalic acid
and ethylene glycol. This gives it a better forming
window than PET.

Physical properties

Those characteristics that define the physical


parameters of a material, such as stiffness, hardness,
impact resistance, chemical resistance, etc. These
properties can be tested and compared to other
materials.

Physical testing

The process of measuring the characteristics of a


material based on standard test methods.

Pimple

A raised area on a sheet of plastic or plastic part


caused by a hardened particle or contaminant within
the matrix of the plastic substrate.

Plastic sheet

A flat piece of plastic having a specific length, width,


thickness and texture.

Plasticizer

A material that can be added to plastics that allow


them to be processed more easily and can change
certain of their physical characteristics such as
toughness or flexibility.

Platen

A movable support mechanism that a plug or mold is


attached to that assists in forming a plastic part.

Plug assist

A mechanical device used in thermoforming to help


distribute the heated plastic sheet more uniformly
before it actually seats on the mold.

Pneumatic

A system where a device is operated via the use of


compressed air.
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Polycarbonate

polyester of carbonic acid produced by using an


interfacial reaction between dihydric or polyhydric
phenols and a suitable carbonate precursor such as
dichlorocarbonate. It is a clear, amorphous material
with good impact strength and a high heat distortion.

Polycarbonate/ABS An alloy of the two different resins that will provide


some unique physical properties depending on the mix
of the two materials.
Polyester

A resin made via the reaction of a dibasic acid and a


dihydroxy alcohol. It is used as a resin base to make
structural parts.

Polyethylene

A thermoplastic material made by polymerization of


ethylene molecules. A large range of polyethylenes
can be made by varying the chain length and additives
to the polymer.

Polymer

A organic substance obtained by joining the same type


of monomers into long chains. For example ethylene is
polymerized into polyethylene through heat, pressure
and catalyzation.

Polymerize

The process of joining numerous like monomers into a


long chain.

Polypropylene

A thermoplastic material made by polymerization of


propylene molecules.

Polystyrene

A clear, amorphous, themoplastic material made by


the polymerization of the sytrene monomer.

Pressure box

The reinforced box that is draped over the mold in the


pressure forming system to provide the added force
required to get good detail from the mold surface.

Pressure forming

A thermoforming technique whereby vacuum and


pressure is used to force the hot plastic sheet against a
mold surface to get a very crisp impression of that
surface.
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Processing

The act of converting a plastic resin or sheet into a


useful form or shape.

Processor

The entity that converts a plastic resin or sheet into a


useful form or shape.

Prototype mold

The mold that is used to make a part that will be


evaluated for fit and function.

Punch press stamping


The process of trimming a formed part by
using a metal die clamped to a movable platen in a
mechanical press. Forcing the platen against a fixed
base pinches the desired surface of the plastic part and
removes the unwanted excess.
PVC

An amorphous thermoplastic material made up of


vinyl chloride polymers. It is widely used in wire
covering and where a chemically resistant plastic is
needed.

PVC/ABS

An alloy of polyvinyl chloride and acrylonitrile


butadiene styrene combined to maximize certain
physical properties.

PVC/Acrylic

An alloy of polyvinyl chloride and acrylic combined


to maximize specific physical properties.

Quartz heaters

A type of heater with about a one-half to three-quarter


inch diameter tube with a resistance wire inside of it
that is backed up by an internal reflector.

Radiant heat

An electromagnetic transfer of energy from a heating


emitter to a material or body one would wish to raise
the temperature of.

Radii

The rounded edges or curvature of the shape being


dealt with. Typically these radii are designed into the
part.

Reflected off energy The small amount of radiant energy directed at a


plastic sheet that is left over from the energy that
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penetrates through the sheet and is absorbed by the


sheet.
Regrind

The plastic materials that are reprocessed into plastic


sheet or finished parts more than once.

Ribs

A raised or depressed area of a formed part that is


designed into it to increase its structural integrity.

Robotic trimming

A mechanized method of performing a secondary


operation on a formed part to enable it to comply with
dimensional specifications.

Router

A high speed air or electrically operated cutting tool


used to trim materials to dimensional specifications.

Sag

The amount of spherical deflection a flat plastic sheet


experiences as it is heated to its forming temperature.

Sag bands

The supporting system that is attached to the clamping


frame to obtain multiple minor sags when using a
multiple cavity mold.

Sandblast

The process of forcefully blowing sand against an


object to clean it or put a fine suede-looking surface
on it.

Screening

The process of blocking out some radiant energy from


reaching the plastic sheet suspended in an oven by
putting in metal window screening between the plastic
sheet and the heating elements used to heat the plastic.

Seal

The edge of a mold base that a hot piece of plastic is


forced against to keep the vacuum enclosed within the
mold chamber while a part is being formed.

Secondary draw ratio

After the initial thickness of plastic is


determined on a formed part, the thickness of any
secondary pockets or protrusions will be determined
by the difference in thickness of the material now
available divided by the area left over on the
secondary area of the part.
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Secondary operations

Those processes that are performed after the


initial forming operation is completed, such as
trimming and assembly.

Shrinkage

The phenomenon whereby a plastic decreases in size


linearly and volumetrically as it is cooled. This term
also refers to the inherent stress put into the extruded
sheet during the manufacturing process.

Snapback

A thermoforming technique that first pre-forms a


bubble into a pre-draw box, then plunges a male mold
into the inside of the bubble, and as a final step,
vacuums the bubble onto the mold.

Stiffness

A measure of the flexibility or rigidity of a material.


This value is usually expressed in terms of flexural
strength or flexural modulus.

Stress

Pressure applied to a given body to deform or fracture


it.

Strength

the ability to withstand force, pressure, or stress. Also


the ability to resist attack.

Symmetrical

An object having a mirror image of itself with respect


to its centerline. One side of the part is identical to the
other side.

Syntactic foam

A combination of inorganic foam spheres in a plastic


foam matrix. This material is used for making
insulative plugs to prevent chill marks.

Temperature controlled aluminum tooling


Molds made with
enclosed tubes buried within their surfaces that allow
cooled or heated water or some other fluid to flow
through them to control the temperature of the mold to
within a few degrees Fahrenheit.
Tensile strength

The pulling force required to stretch or break a given


material. This value is usually expressed in pounds per
square inch.
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Texture (grain)

The pattern embedded into the surface area of a sheet


or part.

Transmitted through

The condition where radiant energy given off


an emitter goes through the object it is hitting rather
than being absorbed or reflected off of that object.

Thermal conductivity

The amount of heat in BTUs which can be


conducted through one square foot of any material one
inch in thickness, in one hour, with one degree
Fahrenheit temperature differential across the
thickness (Btu/hr/ft2/F/in.).

Thermal expansion (Coefficient of) The fractional change in length (or


volume) a one inch object will expanded or contract
with a one degree Fahrenheit change in temperature.
In ABS this value is approximately 5 x 10-5 per inch
per one degree Fahrenheit change in temperature.
Thermoforming

A system of changing a flat sheet of plastic into a


desired shape.

Thermolator system A mechanical device that is used to regulate that


temperature of a fluid that is subsequently pumped
through heating or cooling lines embedded in a mold
to control the mold temperature.
Thinning

The process of taking a finite area of a hot sheet of


plastic and stretching it over a protrusion or cavity of a
larger area and distributing the plastic over this larger
area as best as possible.

Tolerances

The maximum and minimum dimensions that are


required to allow a formed part to be functional.

TPO

Thermoplastic olefin. Essentially it is a polypropylene


blended with and EPDM rubber.

Trim

The excess material around a formed part that is not


part of the finished product. This material is used for
clamping or sealing purposes during the forming
process.
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Undercuts

Those indentations or extensions from a formed part


that prevent the part from being removed from the
mold without providing some type of movable
mechanism on the mold itself.

Unistrut

A U-shaped channel with a clamping bar inside of it


that can be adjusted very quickly by sliding the
clamping bar in either direction of the channel.

UV resistant

The condition whereby a material, in this case plastic,


will resist loosing its physical properties when
exposed to the ultra-violet rays of the sun.

Vacuum

The absence of atmospheric gas within some given


system.

Vacuum box

A five-sided structure on which a heated plastic sheet


can be draped over the sixth side and a partial vacuum
drawn within the box to form an inverted bubble.

Vacuum forming

A method of using vacuum to force heated plastic


against a mold surface.

Vacuum forming techniques


The various sequence of procedures
one can use to shape a heated sheet of plastic to the
configuration of a mold.
Vacuum holes

The holes in a mold which air can pass through to


allow the atmospheric pressure to force the hot plastic
sheet against the mold.

Vacuum seal

The edge around a mold base that the heated plastic


sheet is pressed against to allow a vacuum to be drawn
and force the heated sheet against the mold.

Vacuum system

The mechanism whereby air is removed from an


enclosed chamber to create a vacuum.

Vacuum volume

The size of the enclosed system in which the vacuum


is employed. It also refers to the level of vacuum that
is maintained within the system. Generally a large
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Wo r k b o o k fo r T h e r m o fo r m i n g P ra c t i c a l C o u r s e

(Continued from page 116)

vacuum holding tank is employed to keep the inches


of vacuum from being drawn down to low.
Voids

Small areas within a plastic matrix that have gas


pockets instead of the solid plastic material that should
be there.

Volume resistivity

The resistance of an electrical charge flowing through


the solid structure of the material, in this case plastic.

Warping

The condition whereby a part is dimensionally


distorted from its originally formed shape.

Wavelength

The distance measured from a point on an


electromagnetic wave to the same point on the wave as
it repeats its phase.

Wavelength of energy
A measure of the type of energy given from
various wavelengths of the electromagnetic spectrum.
In plastics we are concerned with the infrared
wavelength band of about .7 microns to about 100
microns.
Weatherable plastics Those plastics that are resistant to physical degrading
when exposed to the ultra-violet rays of the sun.
Weatherability

The ability of a material to resist loosing its physical


properties when exposed to sunlight.

Webs

Excess plastic material that is doubled up on itself and


does not flow uniformly against a mold. It usually
occurs on the corners of parts with small radii.

Wood tooling

Molds made of wood that are usually used to make


prototype parts.

Yield point

That point of stress or strain which if reached will not


allow the material to recover to its original shape. Its
elasticity has been exceeded.

Zones

Those areas in a heating oven that the temperature is


controlled independently from other areas.

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Wo r k b o o k fo r T h e r m o fo r m i n g P ra c t i c a l C o u r s e

REFERENCES
1.

ILLIG Thermoforming - A practical Guide by: Gnter Kiefer/Peter


Schwarzmann

2.

Operating Manual for ILLIG RV 53b Machine- no. 593 EN/04.04-2


edition

3.

Textbooks from SPDC

4.

Various Thermoforming & Vacuum Forming websites from the


internet

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