2. What isThermoforming ?
•Thermoforming is a manufacturing process where
sheets of thermoplastic or films are heated to a pliable
forming temperature, formed to a specific shape in a
mold and trimmed to create a usable product.
Pliable temperature:-
Sag point (above the glass-transition
temperature (𝑇𝑔), of the polymer)
3. Thermoforming Process :
❑Heating plastic sheet to the temperature where it softens.
❑Stretching the softening polymer against a cold mold
surface.
❑Cooling the finished part and trimming excess plastics.
4. Materials Used:
▪ABS (Acrylonitrile butadiene styrene)
▪Cellulose acetate
▪LDPE (Low density polyethylene)
▪HDPE (High density polyethylene)
▪PVC etc.
5. Steps of thermoforming:•
1. Heating:- Heating is accomplished by radiant electric
heater which is located at a distance of 125mm (5 in.)
either on one or both sides of the sheet.
•
2. Forming:- After heating, the polymer sheet is converted
or
formed into various shapes by either air pressure,
vacuum
pressure or by mechanical pressure.
7. Types of thermoforming:
• Basically there are three types of thermoforming processes.
❑Vacuum forming
❑Pressure forming
❑Mechanical thermoforming
8. Vacuum forming
❑It is the earliest method of thermoforming.
❑In vacuum forming, vacuum is created below the preheated
plastic sheet to draw sheet into the cold mold cavity.
❑Basic steps of vacuum forming
1. A flat plastic sheet is heated by radiant heater, which is placed on one or both
sides of the plastic.
2.The softened sheet is placed over a concave cavity.
3.Vacuum draws the sheet to the sheet to the cold cavity .
4.The product is cooled and any extra plastic parts are trimmed
10. Pressure forming❑Alternative to vacuum forming.
❑Here the air pressure is forced to the preheated sheet into a
cold mold. Here the air pressure is much higher than the
vacuum forming.
❑The basic difference from vacuum forming is that the heated
sheet is pressurized from above the mold cavity.
❑Due to high pressure, the heated sheet can be deformed in a
fraction of a second. (High production rate)
12. Mechanical thermoforming❑Here, positive (male) and negative (female) molds are brought
against heated plastic sheet forcing it to the assumed shape.
❑In mechanical forming, air pressure or vacuum pressure are
not used to deform the plastic sheet.
❑Air between the die and sheet is evacuated by using
vacuum pump and the sheet conforms to the mold shape.
❑Formed part is cooled and ejected.
14. Thermoforming:
•
Advantages:
▪ Flexible design
▪ Rapid prototype development
▪ High production rate
▪ Low set up cost
▪ Less thermal stress
Disadvantage:
▪ Not eligible for thermosets
▪ All parts need to be trimmed
▪ Parts may non uniform thickness
15. Applications:
•
Thermoforming has many applications like;
▪Food packaging
▪Automotive parts
▪Aircraft windscreens
▪Trays for cookies and candy
▪Advertising signs
▪Panels for shower stalls
▪Refrigerator liners etc.