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Dash board
Blister packaging
Plastics
Thermoforming
Boat hulls
Disposable tray
Thermoforming
1. Vacuum thermoforming
2. Pressure thermoforming
3. Mechanical thermoforming
Vacuum Forming
• The vacuum forming process can be used to make most product packaging,
speaker casings, and even car dashboards.
Canopy of military
aircraft
Vacuum Forming
Vacuum Forming
• The polystyrene is transparent which means that the mobile phone can be
seen through it.
• This is a skilled job as any imperfections to the mould will show up every
time it is used to shape plastic such as high density polystyrene.
• The mould can be used hundreds and even thousands of times to produce
the same plastic part.
• A sheet of high density polystyrene is placed above the mould and clamped
in position.
• Usually material 1mm thick is the most suitable for this type of vacuum
forming.
Vacuum Forming
• When the machine is being used from ‘cold’ it takes approximately five to
ten minutes to warm up to the temperature needed to heat the polystyrene
sufficiently.
• Once warm, polystyrene of this type takes only four or five minutes to heat
up before vacuum forming can begin.
Vacuum Forming
• The plastic (polystyrene) becomes pliable and flexible after a short time. It
must be very flexible before it can be formed properly.
Vacuum Forming
• When the polystyrene is ready the shelf is then lifted up towards the
polystyrene sheet.
• The air underneath the former is pumped out and the polystyrene takes the
form of the mould.
Vacuum Forming
Shower tray
Vacuum Forming
• A thin sheet is formed into rigid cavities for unit doses of pharmaceuticals.
Bath tray
Vacuum Forming
• Thick sheet is formed into permanent objects such as turnpike signs and
protective covers.
Yogurt pots
Vacuum Forming
Ski-boxes
Vacuum Forming
Refrigerator
liners
Vacuum Forming
Sandwich box
Vacuum Forming
Common Problems:
• Moisture absorption:
– This will be solved by drying the plastic for an extended period at high
but sub-melting temperature.
Common Problems:
• Webbing:
– Webs form around the mold, which is due to overheating the plastic and
so must be carefully monitored.
– Webbing can also occur when a mold is too large or parts of the mold
are too close together.
Common Problems:
• Parts Sticking:
– Objects that are formed often stick to the mold, so make sure there is an
angle of 3 degrees or more.
• In the case of the positive mold, the heated sheet is draped over the convex
form and negative or positive pressure is used to force the plastic against
the mold surface.
• However, if the part is drawn into the negative mold, then its exterior
surface will have the exact surface contour of the mold cavity.
• The inside surface will be an approximation of the contour and will possess
a finish corresponding to that of the staring sheet.
• By contrast, if the sheet is draped over a positive mold, then its interior
surface will be identical to that of the convex mold; and its outside surface
will follow approximately.
• Another difference is in the thinning of the plastic sheet, one of the problems in
thermoforming.
• Unless the contour of the mold is very shallow, there will be significant
thinning of the sheet as it is stretched to conform to the mold contour.
• Positive and negative molds produce a different pattern of thinning in a given
part.
• Consider our tub shaped part as sample.
• In the positive mold, as the sheet is draped over the convex form, the portion
making contact with the top surface (corresponding to the base of the tub)
solidifies quickly and experiences virtually no stretching.
Pressure Thermoforming
• This results in a thick base but with significant thinning in the walls of the
tub.
• In the process, closely controlled air pressure is applied to inflate the soft
sheet.
• The third method uses matching positive and negative molds that are
brought against the heated plastic sheet, forcing it to assume their shape.
• Its advantages are better dimensional control and the opportunity for
surface detailing on both sides of the part.
• The disadvantage is that two mold halves are required; the molds for the
other two methods are therefore less costly.