Professional Documents
Culture Documents
WORKBOOK
for
Thermoforming
Practical Course
Prepared by
Thermoforming Department
1st Edition 2009
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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
ACKNOWLEDGEMENT
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).
Calpe.
April 2009
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TABLE OF CONTENTS
Introduction .
Course Objectives .
Workshop Activities
Activity 1Introduction Basic Principles of Thermoforming ..
16
30
40
53
64
74
83
89
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:
theories
and
practices
of
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ACTIVITIES
GRADE
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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 #1
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 #1Introduction: Basic Principles of Thermoforming
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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 #1Introduction: Basic Principles of Thermoforming
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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 #1Introduction: Basic Principles of Thermoforming
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WORKSHOP ACTIVITY #1Introduction: Basic Principles of Thermoforming
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.
FUNCTION
CYCLE TIME
1.
2.
3.
4.
5.
6.
TOTAL RECORDED CYCLE TIME (STOP WATCH)
TOTAL CYCLE TIME FROM CONTROL PANEL
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WORKSHOP ACTIVITY #1Introduction: Basic Principles of Thermoforming
2.
3.
4.
5.
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WORKSHOP ACTIVITY #1Introduction: Basic Principles of Thermoforming
7.
8.
9.
10.
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WORKSHOP ACTIVITY #1Introduction: Basic Principles of Thermoforming
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___________________________________________________________
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DATE: __________________
TRAINEES SIGNATURE
INSTRUCTORS COMMENTS
TRAINEES GRADE
FOR THIS ACTIVITY
________________________
DATE: __________________
INSTRUCTORS SIGNATURE
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WORKSHOP ACTIVITY #2
Corporate
Management
by Society.
There are no accidents that affect residents and areas around the
factory.
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WORKSHOP ACTIVITY #2Thermoforming General Safety Instructions
Manager/s
Supervisor/s
Personnel
/ Machine
Operators
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.
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WORKSHOP ACTIVITY #2Thermoforming General Safety Instructions
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WORKSHOP ACTIVITY #2Thermoforming General Safety Instructions
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.
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WORKSHOP ACTIVITY #2Thermoforming General Safety Instructions
See Actual
Machine
Part
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WORKSHOP ACTIVITY #2Thermoforming General Safety Instructions
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WORKSHOP ACTIVITY #2Thermoforming General Safety Instructions
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WORKSHOP ACTIVITY #2Thermoforming General Safety Instructions
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.
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.
1. ________________
2. ________________
3. ________________
4. ________________
5. ________________
6. ________________
7. ________________
8. ________________
9. ________________
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WORKSHOP ACTIVITY #2Thermoforming General Safety Instructions
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WORKSHOP ACTIVITY #2Thermoforming General Safety Instructions
No naked lights
Smoke-free rest area
No smoking
Smoking allowed
Mandatory
Safe condition
Warning
Prohibited
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WORKSHOP ACTIVITY #2Thermoforming General Safety Instructions
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___________________________________________________________
________________________
DATE: __________________
TRAINEES SIGNATURE
INSTRUCTORS COMMENTS
TRAINEES GRADE
FOR THIS ACTIVITY
________________________
DATE: __________________
INSTRUCTORS SIGNATURE
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WORKSHOP ACTIVITY #3
This makes these plastics ideal for the vacuum forming process.
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WORKSHOP ACTIVITY #3Materials and Their Applications
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
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 PS125
HI-PS PS330
Transparent
Opaque
7.0 g/10min
4.0 g/10min
12.0 J/M
110.0 J/M
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WORKSHOP ACTIVITY #3Materials and Their Applications
Isotactic polypropylene
- Crystalline plastics
PP Homopolymer
- Transparent, brittle at low temperature
2.
3.
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WORKSHOP ACTIVITY #3Materials and Their Applications
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
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WORKSHOP ACTIVITY #3Materials and Their Applications
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.
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DATA S H E E T
ACTIVITY #3Materials and Their Applications
TRAINEE NAME
GROUP NO.
POLYSTYRENE (PS)
_________________________________________________________________________
_________________________________________________________________________
_________________________________________________________________________
_________________________________________________________________________
_________________________________________________________________________
_________________________________________________________________________
_________________________________________________________________________
_________________________________________________________________________
_________________________________________________________________________
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WORKSHOP ACTIVITY #3Materials and Their Applications
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 #3Materials and Their Applications
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WORKSHOP ACTIVITY #3Materials and Their Applications
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DATE: __________________
TRAINEES SIGNATURE
INSTRUCTORS COMMENTS
TRAINEES GRADE
FOR THIS ACTIVITY
________________________
DATE: __________________
INSTRUCTORS SIGNATURE
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WORKSHOP ACTIVITY #4
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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
Heating Station
Thermoplastic sheet is heated and softened
in this station. The guidelines for heating the
sheet are the following:
Forming Station
In this station, the thermoplastic sheet is
formed into its desired shape, with the required thermoforming process.
Parts of Forming Station:
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
Stacking Station
In this station, the finished products are collected to the desired amount using the
pusher.
Parts of Stacking Station:
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
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.
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
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WORKSHOP ACTIVITY #4The Thermoforming Machine and Mold
Male MoldA male mold or convex mold that has one or more
protrusions over which the heated sheet is drawn to form a shape.
Indirect cooling
Direct cooling
Al tool
With PU tool
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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
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WORKSHOP ACTIVITY #4The Thermoforming Machine and Mold
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:
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:
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.
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
2.
3.
4.
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
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WORKSHOP ACTIVITY #4The Thermoforming Machine and Mold
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DATE: __________________
TRAINEES SIGNATURE
INSTRUCTORS COMMENTS
TRAINEES GRADE
FOR THIS ACTIVITY
________________________
DATE: __________________
INSTRUCTORS SIGNATURE
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WORKSHOP ACTIVITY #5
Heater
Formed Product
Heated Sheet
Female Mold
Vacuum Air
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WORKSHOP ACTIVITY #5Thermoforming Methods & Processes
Pressure Box
Heated Sheet
Pressurized Air
Mold
Vacuum Air
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WORKSHOP ACTIVITY #5Thermoforming Methods & Processes
Mold
Vent
Drape Thermoforming
Matched-Mold Thermoforming
Snap-back Thermoforming
Billow Forming
Twin-Sheet Forming
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WORKSHOP ACTIVITY #5Thermoforming Methods & Processes
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.
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
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DATA S H E E T
ACTIVITY #5Thermoforming Methods & Processes
TRAINEE NAME
GROUP NO.
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
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DATA S H E E T
ACTIVITY #5Thermoforming Methods & Processes
TRAINEE NAME
GROUP NO.
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
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DATA S H E E T
ACTIVITY #5Thermoforming Methods & Processes
TRAINEE NAME
GROUP NO.
Station 2
Station 3
Station 4
Station 5
Station 6
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WORKSHOP ACTIVITY #5Thermoforming Methods & Processes
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
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
b. hold
c. load
d. remove
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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WORKSHOP ACTIVITY #5Thermoforming Methods & Processes
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___________________________________________________________
________________________
DATE: __________________
TRAINEES SIGNATURE
INSTRUCTORS COMMENTS
TRAINEES GRADE
FOR THIS ACTIVITY
________________________
DATE: __________________
INSTRUCTORS SIGNATURE
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WORKSHOP ACTIVITY #6
2.0
3.0
4.0
5.0
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WORKSHOP ACTIVITY #6Manpower and Standard Operating Procedures
When checklist has been complied and everything have been fulfilled, switch on the main power supply and the light switch on.
7.0
8.0
9.0
10.0
Follow the procedure to star the machine and run the machine.
11.0
12.0
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
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WORKSHOP ACTIVITY #6Manpower and Standard Operating Procedures
6
4
5
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WORKSHOP ACTIVITY #6Manpower and Standard Operating Procedures
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WORKSHOP ACTIVITY #6Manpower and Standard Operating Procedures
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.
2.
3.
4.
Open the main air and water supply line by turning ON valve.
5.
6.
7.
8.
9.
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
2.
3.
4.
5.
Check the temperature. When the heating temperature decreases and reached 300C, switch off the chiller.
6.
7.
8.
Do the 5S.
9.
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DATA S H E E T
ACTIVITY #6Manpower and Standard Operating Procedures
TRAINEE NAME
GROUP NO.
Check
2.
3.
4.
5.
6.
7.
8.
9.
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DATA S H E E T
ACTIVITY #6Manpower and Standard Operating Procedures
TRAINEE NAME
GROUP NO.
2.
3.
Check the machine and take-out the products/ skeleton/ runner inside of the machine.
4.
5.
Check the temperature. When the heating temperature decreases and reached 300C, switch off the
chiller.
6.
7.
8.
Do the 5S.
9.
Check
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WORKSHOP ACTIVITY #6Manpower and Standard Operating Procedures
b. run
c. simultaneously run
d. intermittently run
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 #6Manpower and Standard Operating Procedures
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___________________________________________________________
___________________________________________________________
________________________
DATE: __________________
TRAINEES SIGNATURE
INSTRUCTORS COMMENTS
TRAINEES GRADE
FOR THIS ACTIVITY
________________________
DATE: __________________
INSTRUCTORS SIGNATURE
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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 #7
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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
Time
Temperature
Pressure
Speed
Processing Components
Environmental Factors
Climatic conditionsAny change in climatic conditions can change the
process and, accordingly, the quality of the product changes.
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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
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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
Wrinkles
Warped parts
Shrink marks
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.
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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
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
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?
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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
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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
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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
___________________________________________________________
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___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
________________________
DATE: __________________
TRAINEES SIGNATURE
INSTRUCTORS COMMENTS
TRAINEES GRADE
FOR THIS ACTIVITY
________________________
DATE: __________________
INSTRUCTORS SIGNATURE
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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 #8
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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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)
2.
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.
6.
When checklist has been complied and everything have been fulfilled, switch on the main power supply and the light switch.
7.
8.
9.
2.
3.
Check the machine and take-out the products/ skeleton/runner inside of the machine.
4.
5.
6.
7.
8.
Do the 5S.
9.
Page 84
DATA S H E E T
ACTIVITY #8Hands-on and Practical Training (1)
TRAINEE NAME
GROUP NO.
Prepared by :
Checked by :
Thermoforming Senior Instructors
Page 85
DATA S H E E T
ACTIVITY #8Hands-on and Practical Training (1)
TRAINEE NAME
GROUP NO.
Prepared by :
Checked by :
Thermoforming Senior Instructors
Page 86
DATA S H E E T
ACTIVITY #8Hands-on and Practical Training (1)
TRAINEE NAME
GROUP NO.
Time:
Prepared by :
Checked by :
Thermoforming Senior Instructors
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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 #8Hands-on and Practical Training (1)
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
________________________
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
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)
2.
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.
6.
When checklist has been complied and everything have been fulfilled, switch on the main power supply and the light switch.
7.
8.
9.
2.
3.
Check the machine and take-out the products/ skeleton/runner inside of the machine.
4.
5.
6.
7.
8.
Do the 5S.
9.
Page 90
DATA S H E E T
ACTIVITY #9Hands-on and Practical Training (2)
TRAINEE NAME
GROUP NO.
Prepared by :
Checked by :
Thermoforming Senior Instructors
Page 91
DATA S H E E T
ACTIVITY #9Hands-on and Practical Training (2)
TRAINEE NAME
GROUP NO.
Prepared by :
Checked by :
Thermoforming Senior Instructors
Page 92
DATA S H E E T
ACTIVITY #9Hands-on and Practical Training (2)
TRAINEE NAME
GROUP NO.
Time:
Prepared by :
Checked by :
Thermoforming Senior Instructors
Page 93
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)
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
________________________
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
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 95
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)
2.
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.
6.
When checklist has been complied and everything have been fulfilled, switch on the main power supply and the light switch.
7.
8.
9.
2.
3.
Check the machine and take-out the products/ skeleton/runner inside of the machine.
4.
5.
6.
7.
8.
Do the 5S.
9.
Page 96
DATA S H E E T
ACTIVITY #10Hands-on and Practical Training (3)
TRAINEE NAME
GROUP NO.
Prepared by :
Checked by :
Thermoforming Senior Instructors
Page 97
DATA S H E E T
ACTIVITY #10Hands-on and Practical Training (3)
TRAINEE NAME
GROUP NO.
Prepared by :
Checked by :
Thermoforming Senior Instructors
Page 98
DATA S H E E T
ACTIVITY #10Hands-on and Practical Training (3)
TRAINEE NAME
GROUP NO.
Time:
Prepared by :
Checked by :
Thermoforming Senior Instructors
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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 #10Hands-on and Practical Training (3)
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___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
________________________
DATE: __________________
TRAINEES SIGNATURE
INSTRUCTORS COMMENTS
TRAINEES GRADE
FOR THIS ACTIVITY
________________________
DATE: __________________
INSTRUCTORS SIGNATURE
Page 100
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
Acrylonitrile-Butadiene-Styrene terpolymer
Absorption
Air convection
Air convection oven The chamber or structure used to deliver hot air to the
surface of a plastic.
AES
Alkali
Alloy
Amorphous polymers
ASA
Atmospheric pressure
Banbury mixing
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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
Billow
Black body
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
Blisters
Bridging
Bubble
Calrod
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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
Ceramic heater
Chain drive
Chemical reactor
Page 103
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
Commodity materials
Conduction
Conductive plastics
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
Cooling
Cooling lines
Cooling fixture
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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
Die cutting
Die lines
Dimple
Discoloration
Draft
Drape
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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
Emissivity
Entropy
EPDM
Epoxy resin
Excessive moisture
Female mold
Fiberglass
Flammability
Page 106
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
Forming technique
Gas regulator
Gels
Heating profile
Heater types
Page 107
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
Hydraulic
Hygroscopic
Impact strength
KORAD
Louvers
Male mold
Materials
Material distribution
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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
Micro-switch
Moat
Mold
Mold base
Mold shrinkage
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
Olefins
Orientation
Page 109
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
Percentage timer
PETG
Physical properties
Physical testing
Pimple
Plastic sheet
Plasticizer
Platen
Plug assist
Pneumatic
Page 110
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
Polycarbonate
Polyethylene
Polymer
Polymerize
Polypropylene
Polystyrene
Pressure box
Pressure forming
Page 111
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
Processing
Processor
Prototype mold
PVC/ABS
PVC/Acrylic
Quartz heaters
Radiant heat
Radii
Page 112
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
Ribs
Robotic trimming
Router
Sag
Sag bands
Sandblast
Screening
Seal
Page 113
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
Secondary operations
Shrinkage
Snapback
Stiffness
Stress
Strength
Symmetrical
Syntactic foam
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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
Texture (grain)
Transmitted through
Thermal conductivity
Tolerances
TPO
Trim
Page 115
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
Undercuts
Unistrut
UV resistant
Vacuum
Vacuum box
Vacuum forming
Vacuum seal
Vacuum system
Vacuum volume
Page 116
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
Volume resistivity
Warping
Wavelength
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
Webs
Wood tooling
Yield point
Zones
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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.
2.
3.
4.
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