Clem plastic shaping

CLEM
CLEM
Overview thermoplastics

• PS • PE
• ABS • PMMA
• PVC • PC
• PP • PET
– C extrusion
Co t i
– Blends

CLEM N.V. Spinnerijkaai 39, B-8500 Kortrijk

PS Polystyrene
• Properties
– Very well deformable
V ll d f bl
– Dimensionally stable
– High gloss
– Cheap
– Not very chemical resistant
– Not i t t t
N t resistant to UV


PS Polystyrene
• Applications
– Food
F d & medical packaging
di l k i
– Toys
– Electronic housings
– Displays
– Refridgerator interiors


ABS Acryl Butadiene Styrene
• Properties
– Impact resistant
I i
– Well deformable
– Easy to glue
– Modified = limited outside use
– Fairly chemical resistant


ABS Acryl Butadiene Styrene
• Applications
– Automotive industry
A i i d
– Electronic houdings
– Machinery
– Available with special properties like fire
retardant and antistatic


PVC Poly Vinyl Chloride
• Properties
– Good i
G d resistance to li h and humidity
light d h idi
– Strong and not brittle
– Optical transparancy is possible
– Long life span
– Fairly chemical resistant
– Chloride li k
Chl id links are released through burning
l d th hb i


PVC Poly Vinyl Chloride
• Applications
– Roof
R f gutters and d i pipes
d drain i
– Outside doors
– Machinery
– Electrical insulation
– Medical housings (fire safety)


PP Polypropylene
• Properties
– Resistant to high temperatures
R i hi h
– Ductile
– Not sensitive to aging
– Cheap
– No well thermoformable


PP Polypropylene
• Applications
– Food
F d
– Automotive
– Technical products
– Packaging


PE Polyethylene
• Properties
– Very i
V impact resistant
i
– Very resistant to UV (black)
– Very chemical resistant
– Hard to glue
– Bad form stability
– Resistant t h idit
R i t t to humidity


PE Polyethylene
• Applications
– Roof il
R f tiles
– Automotive
– Transport trays
– Machine parts
– Safety hoods


PMMA Polymethylmethacrylate
• Properties
– Clear
Cl transparant
– Very printable
– Easy to deform
– Not so impact resistant
– UV stabile and colourfast
– Cast
C t & extruded quality
t d d lit


PMMA Polymethylmethacrylate
• Applications
– Light d
Li h advertising
ii
– Transparant hoods for machines
– Baths & showers
– Roof domes
– Design lighting


PC Polycarbonate
• Properties
– Very i
V impact resistant with high/low temp’s
i i h hi h/l ’
– High temperature resistance: 140°C
– Very transparant
– Suited for exterior with a UV coating
– Good fire resistance
– Humidity b b t
H idit absorbant
– Relative expensive


PC Polycarbonate
• Applications
– Machinery
M hi
– Transparant parts for exteriors (anti vandalism)
– Lighting (fire resistant)
– Safety windows
– Safety helmets


PET Poly Ethene Tereftalate
• Properties
– Good
G d transparancy
– Low temperature resistance: 65°C
– Very tough
– Good thermoformable
– Good chemical resistance
– Formfast
F f t
– Good fire resistance


PET Poly Ethene Tereftalate
• Applications
– Packaging
P k i
– Food
– Bottles for softdrinks
– Displays
– Cable insulation


Hybrids
• Blends: ABS,PC/ABS,PS/PP,KYDEX,
TPO
• Co extrusion: ABS/PMMA
• Combined sheets: PE + 3mm foam


Bayloy ®
• Bayloy 10: opaque coloured polycarbonate
sheets
• Bayloy 21: PC/PETG blend
• Bayloy 40: opaque APET sheets
• B l 50: opaque coloured PETG sheets
Bayloy 50 l d h t
• Bayblend: PC/ABS blend
y


Kydex
• Properties
– Impact resistant
I i – Stiffness
S iff
– Fire resistant – Resilient
– Chemical resistance – Dimensional stability
– Very good – Easy to colour
thermoformable – Low minimal order
– No pre-drying needed
pre drying quantity
– Abrasive resistance


CLEM
CLEM
VACUUM FORMING

dHr. Verheust V.


Overview
• Vacuum forming ?

• Commonly used techniques

• Design: opportunities  restrictions

• Finishing
g

• Projects
j

Vacuum forming ?
Thermoplastic, semimanufactured product
in plate form
p

3-D product


Vacuum forming - process
3 stages in the process
Heating up Forming Cooling

(plate thickness, sort of material)
thickness
(form  place dependent)


Forming
Mould
Heated plate

Clamp system
p y

Temp. control
channels

Vacuum channel


Forming machines
2 basic concepts

• Single-station
(discontinuous)

• Multi-station
(q
(quasi-continuous)
)


Forming machines
Single-station Multi-station (carrousel)

1 treatment station 3 different treatment stations
(loading/unloading, heating, forming)


Commonly used techniques
• Positive forming
– Usual positive forming
– Forming using pre-blowing
– Forming a vacuum

• Negative forming
– Usual negative forming
– Forming with stamp
– Forming using pre-blowing, stamp and vacuum

• Hi h pressure f
High forming (HPF)
i
• Twin sheet forming
g

Usual positive forming

Heating

Elastic

Forming
i


Usual positive forming

improvement via
• V i bl wall thickness 
Variable ll hi k
pre-blowing or
vacuum
• Inside – correct dimensions


Application


Positive forming + pre-blowing
• Better division of wall thickness via pre-
blowing

1. Pre-blowing

2. Vacuum


Positive forming + pre-blowing


Applications


Positive forming + vacuum
• Better division of wall thickness via vacuum

Vacuum


Application

Lighting hood
(base: 500 x 350)
(height:
(h i ht 600)


Negative forming

Variable wall thickness

Vacuum


Negative forming

Improvement via
• Variable wall thickness 
stamp

• Outside – correct dimensions

Negative with stamp
• Better division of wall thickness via stamp

1. Stamp
stretching

2. V
2 Vacuum


Negative forming with pre
pre-
blowing, stamp and vacuum
• Better division of wall thickness

1. Pre-blowing

2. St
2 Stamp
stretching

3. Vacuum


High pressure forming (HPF)
At atmosphere High pressure

Acute
A t angles?
l ? •Almost always negative
•Acute angles  no problem
•Adding texture to the surface is
possible


Negative HPF
• Variable wall thickness
• Adding texture to the surface is possible


Negative HPF with stamp
• Better division of wall thickness via stamp
• Adding texture to the surface is possible


Twin sheet forming
• 2 sheets are heated up simultaneously +
formed + welded


Design:
opportunities  restrictions
• Variable wall thickness

Positive Negative

• 1 side with correct dimensions as a result of
contact with mould

Design:
• Ideal angle
g
135 °, ideal 90°, good 60°, to be avoided

to be avoided better best


Design:
• Conics

• A id undercuts, though they are possible
Avoid d t th h th ibl


Design:
• Depth of draw
p
Stamp
necessary ?

•S
Secondary d
d draw Strong thinning of
wall thickness

Stamp from above
with controlled
ih ll d
temperature

Design:
• Draw ratio

sum of all surfaces initial thickness
Draw ratio = =
initial surface average final thickness


Finishing
From plate to final product

Vacuum forming with
automatic loader


Finishing
From plate to final product

5-axis milling 3D measurement
bench


Projects
• Realised projects in very diverse domains
– Medical sector
– Automotive sector / transport
– Industry
– Design & display
– Art
– ...


Projects
• Medical sector

Part of radiology device Communication aid


Projects
• Automotive sector / transport

Bodywork Roof part


Projects
• Industry

Housing of a loom Internal door


Projects
• Design & display


Projects
• Art

Pieces of scenery


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