Professional Documents
Culture Documents
18-4 Heaters
Types of heat sources are described with an explanation of how they transfer energy.
25-2 Corners
Corners in a thermoformed part should be designed to avoid material thinning (in a female
part). This sometimes conflicts with the design requirements or volume calculations of a
container. This is discussed in general terms here.
Thermoformable Polymers
Although we generally consider the words
“plastics” and ”polymers” interchangeable,
the term “plastics” refers to the product
delivered as resin pellets or sheet. Nearly all
plastics contain “polymers,” the pure long-chain
hydrocarbons, but they also contain shopping
lists of additives such as thermal stabilizers,
antioxidants, color correcting dyes, sition occurs over several degrees of blended polymer is modified poly-
internal and external processing temperature, and again usually only phenylene oxide or mPPO, which
aids, as well as product-specific one temperature value is reported as is a near-equal blend of polystyrene
additives such as fire retardants, the “melt temperature.” Polymers and polyphenylene oxide. mPPO is
colorants, UV stabilizers and fillers. that have both glass transition and desired for its good impact resistance
However, because the term “plastic” melt temperatures are called “crys- and fire retardancy.
connotes cheapness and poor quality, talline polymers.” Polyethylene and The “thermoforming window” is
the industry is now calling all poly- polypropylene are examples of crys- the temperature range over which
meric materials “polymers.” talline polymers. the polymer is sufficiently subtle or
There are two general categories If only one polymer is used in a deformable for stretching and shaping
of polymers. When the polymer can given plastic recipe, the polymer is into the desired shape. Typically,
be heated and shaped many times called a “homopolymer.” Examples amorphous polymers have broader
without substantial change in its of homopolymers include general thermoforming windows than
characteristic, it is a “thermoplas- purpose polystyrene [GPPS or some- crystalline polymers. Polystyrene,
tic.” When the polymer cannot be times called “crystal polystyrene” for example, can be formed from
reshaped after being heated and because parts made of the unpig- around 260°F or about 50°F above
shaped the first time, it is a “ther- mented water-white polymer have its glass transition temperature to
moset.” Thermoforming is primarily the appearance of fine crystal], low- about 360°F or only a few degrees
concerned with thermoplastics. density polyethylene or LDPE and below the temperature where it is
Thermoformers use two general polyethylene terephthalate or PET. If injection moldable. Polypropylene
types of polymers. When a polymer one polymer is reacted with another, homopolymer, on the other hand, is
is heated from very low tempera- the polymer is called a “copolymer.” so fluid above its melting temperature
ture, it undergoes a transition from Impact polystyrene or HIPS is an of 330°F that its thermoforming
its glassy state to a rubbery state. example of polystyrene reacted with window may be no more than
Although this transition occurs a rubber such as butadiene. Many one degree or so. As a result, it is
over several degrees of temperature, copolymers are used in thermoform- frequently formed just below its
usually only one temperature value ing, including polypropylene-poly- melting temperature. Even then,
is reported as the “glass transition ethylene and PVC-PMMA. its thermoforming window
temperature.” Polymers that only If three polymers are reacted may be only two or three
have a glass transition temperature together, degrees. ■
are called “amorphous polymers.” the
Keywords: amorphous,
Polystyrene, ABS, PVC and polycar- polymer
crystalline, glass
bonate are examples of amorphous is called a
transition temperature,
polymers. 80% of all polymers ther- “terpolymer.” The
melting temperature,
moformed are amorphous polymers. classic terpolymer is
homopolymer,
80% of all amorphous polymers are ABS, which is a reacted
copolymer, terpolymer,
styrenic, that is, polystyrene, impact product of Acrylonitrile,
blend, thermoforming
polystyrene, ABS, and other similar Butadiene and Styrene.
window
polymers. Occasionally, two poly-
Certain polymers exhibit a second mers are extrusion- or melt-
transition, from the rubbery state to a blended together to make
molten or melt state. Again, this tran- a plastic recipe. The classic
Polymer Properties
Thermoforming involves stretching of rub-
bery solid plastic sheet. When force is applied
to any material, it stretches or elongates. The
amount that it stretches depends on the amount
of force per unit area, or “stress,” applied to the
sheet, the nature of the material and its tem-
perature. The amount that the material stretches
is elongation or “strain.” For most important, however. If the softening orientation and internal stresses in
metals, ceramics and many polymers range of the polymer is too narrow, sheet can be traced back to the vis-
below their glass transition tempera- that is, the polymer goes from being cosity of the polymer at the time of
tures, the amount of strain in the ma- very stiff to extremely soft over a extrusion.
terial is proportional to the amount very narrow temperature range, the Frequently thermoformers are told
of stress applied to the material. The thermoforming window will be very to use a polymer with a given “melt
proportionality is referred to as the narrow. This is the case with most index.” The melt index test was estab-
material “modulus.” The modulus grades of nylon 6, for example. And if lished years ago as a quick check of
of a given polymer depends on the the stress or force per unit area needed the flowability of polyethylene melt.
molecular make-up of the polymer, to stretch the polymer is always very Basically it is the amount of molten
the nature and level of the additives high, regardless of the polymer tem- plastic, in grams, at a prescribed
in the polymer and the temperature of perature, traditional vacuum forming temperature that can be squeezed
the polymer. For example, according and even normal pressure forming through a hole of a given diameter
to Modern Plastics Encyclopedia, the pressures may be insufficient to in ten minutes. Ten grams of a poly-
ASTM D638 range in modulus of PS stretch the polymeric sheet to the far- ethylene with a melt index of 10, say,
at room temperature [77°F or 25°C] is thest reaches of the mold. This is the will extrude through the hole in ten
330,000 to 475,000 psi. case for many classes of highly filled minutes, whereas only 1 gram of a
For many polymers, the stress- and fiber-reinforced polymers. polyethylene with a melt index of 1
strain curve is not linear, but is Again, thermoforming focuses on will extrude through the same hole
curved. The room temperature modu- the solid properties of a polymer, such in the same period of time. Thus, the
lus for LDPE, for example, is oven as stress-strain. Nevertheless the fluid polymer with the greater melt index
in Modern Plastics Encyclopedia as properties of the polymer are impor- value will flow more rapidly at the
25,000 to 41,000 psi. But at room tant as well. After all, the polymer same stress level and therefore, will
temperature, LDPE is far above its must be extruded into sheet. Fluid have a lower viscosity. For a given
glass transition temperature of -25°C. properties of polymers are related type of polymer, a lower viscosity
Therefore, reported modulus is the to the polymer liquid resistance to usually means a lower molecular
slope of the stress-strain curve at zero applied stress. The polymer liquid weight. Extruders prefer polymers
strain. Furthermore, as the polymer resistance is given as “rate of strain” with relatively high melt indexes.
is heated above its glass transition and “viscosity” is the slope of the Keep in mind, however, that melt
temperature, the stress-strain curve stress-rate of strain curve. As with index gives very little informa-
remains curved but flattens. The solid polymer stress-strain tion about temperature- and
modulus, being the slope of the curve curves, liquid shear rate-dependent nature
at zero strain, also decreases with polymer of the viscosity of a given
increasing temperature. In addition, stress-rate polymer. And extending
the elongation at break increases with of strain the concept of melt index
increasing temperature. curves are tem- beyond polyethylenes and
The decreasing modulus, the flat- perature dependent, polypropylenes is risky, at
tening of the stress-strain curve, and with polymer viscos- best. ■
the increasing elongation at break of ity decreasing with
Keywords: modulus,
a given polymer or polymer recipe increasing temperature.
viscosity, stress, strain,
with increasing temperature are all Very high viscosity, being
stress-strain curve,
important in thermoforming, because a measure of the polymer
stress-rate of strain
the sheet must be stretched into the liquid resistance to applied
curve, melt index
deepest recesses of a mold. Two other stress, can lead to
aspects of the stress-strain charac- sheet extrusion problems. So can
teristics of a given polymer are also very low viscosity. Unwanted
Polymer Properties II
In addition to stress-strain and stress-rate
of strain characteristics of polymers, thermo-
formers need to know about the thermal prop-
erties of polymers.
“Heat capacity” is a measure of the amount
of energy required to elevate the polymer tem-
perature. Heat capacity is sometimes called
“specific heat.” The field of study the temperature approaches the melt sition temperature, the slope of the
that focuses on energy uptake of ma- temperature of the polymer. temperature-dependent specific vol-
terials is called “Thermodynamics.” “Thermal conductivity” is the ume curve changes perceptively. In
In thermodynamics, one of the fun- measure of energy transmission the vicinity of the melt temperature,
damental measures of energy uptake through a material. The thermal the slope changes dramatically. Typi-
is “enthalpy.” Enthalpy increases conductivity values of organics, in cally, the density of an amorphous
with increasing temperature. When general, are substantially lower, by polymer at its forming temperature
a material goes through a charac- orders of magnitude, than, say, is about 10% to 15% less than that
teristic change such as melting, the metals. In other words, polymers at room temperature. The density
temperature-dependent enthalpic are thermal insulators. As an ex- of a crystalline polymer at its form-
curve changes dramatically. When ample, the thermal conductivity ing temperature may be as much
a material goes through a character- of aluminum, a common metal for as 25% less than that at room tem-
istic change such as glass-to-rubber thermoforming molds, is one-thou- perature. Obviously as the polymer
transition, the temperature-depen- sand times greater than the thermal cools from its forming temperature,
dent enthalpic curve changes subtly conductivity of, say, polystyrene. its density will increase, its volume
if at all. As expected, it takes far more During thermoforming, thermal will decrease, the final part dimen-
conductivity is a measure of energy sions will decrease and the part will
energy to heat a crystalline polymer
transmission through the polymer exhibit shrinkage. This point will be
from room temperature, say, to
sheet. Even though the thermal amplified in later articles.
above its melt temperature than to
conductivities of polymers are low, “Thermal diffusivity” is a poly-
heat an amorphous polymer from
there are differences in values among mer property that is a combina-
room temperature to the same tem-
polymers. For instance, the thermal tion of other polymer properties.
perature. For example, it takes more conductivity of HDPE is about four Thermal diffusivity is divided by
than twice as much energy to heat times higher than polystyrene or its density and specific heat, and is
polyethylene, a crystalline polymer, ABS. Thermal conductivity and its the fundamental polymer property
to 360°F than it does to heat poly- companion property, thermal dif- in time-dependent heat transfer to
styrene to the same temperature. fusivity, discussed below, are quite materials. Because of the unique
And since the formed shape must be important when forming very thick bundling of temperature-
cooled, twice as much energy must sheets, because the rate of energy dependent characteris-
be removed to cool polyethylene transfer into the sheet gov- tics of the polymer
to a given temperature than to cool erns, to a large properties, thermal
polystyrene to the same tempera- extent, the diffusivity is nearly
ture. A single value of specific heat is formability of independent of tem-
frequently given for a specific poly- the sheet. Although perature for nearly
mer. These values are determined thermal conductivity all polymers.
by dividing the enthalpy difference typically decreases slightly ■
by the temperature difference. Such with increasing temperature, Keywords:
values are acceptable for amorphous for all intents, the value can be Heat capacity,
polymers but care must be taken considered constant. specific heat,
with a crystalline polymer, since the Polymer density decreases and enthalpy, thermal
its reciprocal, “specific volume,” conductivity,
slope of the temperature-dependent specific volume,
enthalpy curve, and hence the spe- increases with increasing tempera-
thermal diffusivity
cific heat, changes dramatically as ture. In the vicinity of the glass tran-
Mold Materials
Most commercial thermoforming manner as water lines are drilled in
molds are made from aluminum. injection molds.
Aluminum is used because it is light, In certain instances, other metals
it is easily worked, is relatively inex- are used for molds. For composites, There
pensive and has a very high thermal for example, temperature and pres- are even
conductivity. It is also used because sure requirements may preclude the more
the forming forces against the finished use of aluminum. Steel, particularly materials
mold are low when compared with, chrome-plated steel, and stainless available for
say, injection molding. steel are good alternatives. Steel has straight vacuum
Larger commercial molds are usu- about one-third the thermal conduc- formed prototype
ally cast from the melt. In addition tivity of aluminum and about twice parts. Wood is an
to the common atmospheric casting, the modulus. Stainless steel has about obvious choice,
molds can be made by vacuum casting one-fifth the thermal conductivity of
with ash and hard
and pressure casting. Smaller molds aluminum and about 50% greater
maple offering the
are frequently machined from plate. modulus.
best balance of properties such as
Computer-controlled machining Because thermoforming pressures
compression strength, shaping and
stations have made manufacture of are relatively low, usually not exceed-
sanding quality and resistance to
many-cavity molds quite competitive ing 100 psi, many other materials
splitting, checking, and warping.
with other means of manufacture. can be used for molds. Although
Hydrocal is a dense industrial plaster
For the most part, thermoforming electroformed nickel is much more
that makes a high quality mold. Plas-
molds are single-surfaced. That is, one expensive than other metals, it is used
ter mold fabrication is quick, with the
surface of the plastic sheet is forced when extremely high detail is needed
primary drawbacks being the messy
against the mold surface, while the or when a very intricate pattern must
nature of plastic casting, including
other surface is “free” or untouched be replicated. Very large parts, such as
plastic dust, weight [compared with
by another mold surface. In certain exterior door panels, have been made
wood], and brittleness.
instances, such as foam and com- on electroformed nickel tools. Usually
More recently, medium density
posite forming, the sheet is so stiff at nickel is electroformed onto a pattern,
fiberboard or MDF has found ex-
the forming temperature that it must water lines are placed against the
tensive use, primarily for shallow
be pressed between two “matched nickel shell, then the nickel is backed
draw and male molds, since it can
mold” surfaces in order to accurately with a cheaper white metal.
be quickly worked with traditional
form the part. Sprayed metal is also used for
woodworking tools and has no grain
In large, cast molds, water lines are prototyping and limited produc-
and no propensity to warp, split or
typically attached to the reverse sides tion. Molten white metal such as
check. It is relatively expensive and
by soldering or secondary casting. In zinc is atomized and atmospheri-
restricted in thickness. Syntactic
smaller, machined molds, cooling is cally sprayed against a pattern in
epoxy or polyester foam was
frequently done through flood plates a fashion similar to paint spraying
originally developed as a plug assist
attached to the rear of the molds. or polyester spraying. A reasonably
material but is now computer-driven
When water lines are needed, for thick layer of metal can be sprayed in
machined into smaller molds. It can
deeply drawn parts, they are gun- a reasonably short time. Water lines
be expensive, particularly if a substan-
bore drilled in, in much the same are placed against the metal shell and
tial amount of the initial billet must be
sprayed in place. This is
machined away to make the mold.
then backed wither with
■
metal-filled epoxy or pot
metal. Many sprayed Keywords: cast aluminum,
metal applications have machined aluminum, computer-
been taken over by com- driven machining, chrome-plated
puter-driven machining, steel, stainless steel, electroformed
and so typical sprayed nickel, hydrocal, medium density
metal molds today fiberboard, syntactic foam, sprayed
are small and highly metal
detailed.
Heaters
to age quickly, have poor temperature control, cannot be
easily zoned, but are extremely rugged and relatively inex-
pensive. Quartz and halogen heaters are basically nichrome
or tungsten wires in quartz glass tubes. These heaters are
known for their very short heat-up times, excellent tem-
perature control, and very high temperature capability, but
they are very fragile, the glass is easily etched, and they
are very expensive. Panel heaters include coated metal
plates that reradiate heat from nichrome wires embed-
ded in ceramic, quartz glass and quartz cloth plates that
transmit heat from similarly embedded nichrome wires.
Panel heaters have moderately long heat-up times, good
There are three primary energy sources for heating plas- temperature control, and excellent longevity, but they
tic sheet in thermoforming. Electric heat is used more than are difficult to zone effectively. Ceramic bricks that have
gas heat or hot fluid heat. Some common heating sources embedded heating wires are reasonably rugged, have
include hot air, hot water or steam, sun lamps, nichrome moderate heat-up times, excellent temperature control and
spiral wire or toaster wire, steel rod heaters, steel or ni- moderate longevity, but they are fragile and it is difficult
chrome tape, tungsten and halogen tube heaters, quartz to determine burn-out.
tube heaters with nichrome or tungsten wire or tape, steel
plates with embedded resistance wire, ceramic plates with Combustion Heating
embedded resistance wire, ceramic bricks with embedded The “2000 Years of Thermoforming” cartoon on the 1996
resistance wire, ceramic bricks with embedded resistance SPE Thermoforming Division tee-shirt depicted a caveman
wire, steel plates that reradiate combustion energy from gas stomping on a sheet of plastic suspended over a roaring
flame, indirect gas combustion on catalytic beds and direct fire. Direct gas heating using natural gas or propane rather
gas combustion energy. Keep in mind that all hot surfaces than wood is a viable way of heating plastic. However the
transfer energy by conduction, convection and radiation. energy output from direct combustion is very high and
sheet scorching or ignition is always a concern. Indirect
Hot Fluid Heating catalytic heaters provide a more uniform energy source,
Recirculating hot air or forced convection ovens are used although energy output is admittedly less than that for
when heating times are not critical or when sheet is very electric heaters, and, until recently, temperature control
thick, usually greater than 0.500 inches. There are several was “on-off.” Installation cost is higher than that for elec-
oven designs in use. Air is blown across metal coils and then tric heaters, but energy costs are as low as 20% of that for
across the sheet in indirect electric ovens. Electric panels, equivalent output electric heaters. Catalyst longevity was
usually in the top of the oven, are combined with fan-cir- problematical early on, but fourth generation catalysts ap-
culated air in direct electric ovens. Architectural products pear to have minimized loss in efficiency and formation of
such as commercial or industrial skylights, soaking tubs hot spots. High pressure indirect gas combustors known
and whirlpools are frequently made using these methods as ported surface burners are currently being tested as an
of heating. Direct gas-fired heaters similar to those used alternative to the high-energy electric heaters.
in rotational molding ovens, are used to heat plastics such
as polyethylene that are not easily oxidized or chemically Selection of the “Correct” Heater
attacked by combustion products. There is no “correct” heater. Heater
selection depends on many intrinsic and
Direct Contact Heating extrinsic factors including retrofit-
Direct contact heating is used extensively for very thin ting, sheet geometric char-
sheet or thermally sensitive polymers. For a very short acteristics including
time, the sheet is brought in contact with a heated PTFE- thickness, polymer
coated metal plate. It is then quickly formed against the thermal sensitivity,
mold. Direct contact heating is a common heating method day-to-day running costs,
in form, fill and seal (FFS) machines, where the sheet may maintenance costs, initial in-
be heated sequentially on both sides, by running it against stallation cost, versatility of the
heated rolls. Oriented Pet such as Mylar™, oriented poly- heater, and the inherent design
styrene (OPS), nylon 6, 66 and 11, some calendered PVC, of the thermoforming machine
and cast polyimide such as Kapton™ are heated using and its surroundings. ■
direct contact heating.
Keywords: Electric heat, gas heat,
Electric Heaters fluid heat, direct contact heat,
Electric heaters can be categorized as round heaters, such nichrome, tungsten, quartz, halogen,
as wire, rod or quartz heaters, and flat heaters such as panel catalytic heater
heaters. Metal rod heaters have long heat-up times, tend
10 [This is one in a series of articles introducing general concepts in thermoforming.]
Oven Design
“B movie” science-fiction-like wall of
hundreds of adjustable dials. Now,
THERMOFORMING most small heaters are “clustered”
into a more manageable number of
101 controllable “zones” which are then
adjustable through a digital or even
touch-screen monitor at the process
near the sheet edges. This helps control station. PID controllers are
minimize heater inefficiency along a must for heaters that require rapid
sheet edges. Usually the heaters are changes in power level. These con-
fixed in position relative to the sheet trollers minimize power overshoot.
plane. However, machines have been This minimizes sheet overheating
built in which the lower heaters travel and extends the lifetime of the heater
downward as the heating sheet sags. element
1
In truth, the “smoke” is probably not polymer decomposition products being evolved but volatile additives such as internal or external
lubricants or processing aids.
1
Residual stress, orientation and shrinkage are addressed in a future tutorial.
2
A. Buckel, “Comparison of American and European Heavy-Gauge Thermoforming Machines”, TFQ 18:3, 1999, p. 13.
1
The pressure difference between atmospheric pressure on one side of the sheet and vacuum on the other is referred to as “differential
pressure.”
2
The shape of the sheet is similar to the shape taken by a freely hanging chain or rope held by both ends.
Trimming - iI - THIN-GAUGE1
What is Used to Trim forced against the trim die line. If the the web. With micrometer gapping on
press employs matched metal dies, new presses, millions of cuts without
Thin Sheet? the cutting die edge squeezes the replacing the dies are possible. Steel
The steel rule die is the most com- sheet against a steel backing plate rule dies and forged dies are used in
mon method of trimming thin-gauge until it is cut through. The steel back- in-mold trimming.
sheet. The steel rule die is basically a ing plate is usually spring-loaded
special-grade steel strip that has been so that the cutting die edge is not Successful Thin-Gauge
sharpened on one edge. The strip is striking an immovable surface. If
bent to the contours of the trim line on the press employs a punch-and-die Trimming
the part. It is then mounted in a base Typical thin-
plate. This assembly is then attached gauge trimming
to the trim platen. The spe- problems are an-
cific details about the steel gel hair or very
rule die, the base plate THERMOFORMING fine fibers, fuzz,
and the assembly depend
strongly on the trimming 101 dust, and edge
microcracks.
equipment. For high pro- These are usu-
duction, punch-and-die ally related to
or matched metal die a mismatch be-
assemblies are used. For tween the nature
these assemblies, sharp- of the cutting edge of the trim die and
ened machined or forged the cutting characteristics of the poly-
hardened steel dies are used. arrangement, the punching die edge mer. Cutting edge sharpness is always
essentially pinches the plastic against critical, but so is the edge bevel. And
an immovable die. As the plastic is cut
Thin-Gauge Trim through, the punch passes inside the
the rigidity and planarity of the trim
die is also important, particularly for
Techniques immovable die. deep and very long, linear cuts. As
The simplest thin-gauge trimming There are horizontal trim presses, we discussed in the first part, soft,
machine consists of a horizontal mo- where the plastic sheet is fed verti- gummy plastics tend to “flow” away
tor-driven roller and a rigid table. The cally into the horizontally reciprocat- from the cutting edge, whereas brittle
gap between the roller and the table ing platens, and vertical trim presses, plastics tend to form dust and edge
is manually adjustable. The sheet where the plastic is fed horizontally cracks. Certain polymers, such as PET
containing the formed parts is placed into vertically reciprocating platens. and PETG, benefit by being cut hotter,
in a fixture and a base plate, usually For parts where holes and slots are but that is not always possible.
of plywood, containing the steel rule needed, multiple trim presses are Registration problems can be severe
die, is placed atop the plastic and used. The first press cuts the slots or if the plastic has significant shrink-
fixture. The entire assembly is then holes and the second press trims the age and orientation after leaving
hand-fed through the roller. The nip part from the web. the forming press. PP and CPET are
pressure forces the steel rule die into There are many other trim tech- classic examples. Even with multiple
the plastic and the parts are cut free. niques that fall between the hand-op- molded-in registration posts, sub-
This technique is ideal for prototype erated trim press and the automated stantial set-up time may be needed
operation. in-line multiple trim press. For ex- to correctly position the in-line trim
At the other end of the spectrum, ample, in-mold or in-situ trimming dies. Small processing changes, such
trimming presses are employed. The has become popular, following its as sheet temperature, forming time,
sheet containing the formed parts is acceptance in Europe more than a and mold temperature, may lead to
fed continuously between recipro- decade ago. Here, the trim die is part mis-registration. ■
cating platens. A steel cutting die is of the mold. As the sheet is stationed
over the mold cavity, the trim die Keywords: steel rule die, forged
1
Ed. Note: In the first part of this three-part
moves against it, pinning it to the die, machined die, trim press, trim
series, we defined trimming as the means mold cavity. In this fashion it acts problems
of separating the formed plastic part from as a hold-down fixture, cavity isola-
the web, skeleton, or unformed sheet tor, or grid. Once the part has been
surrounding it. In this part, we consider formed, the trim die continues into
methods of trimming thin-gauge parts. the plastic, separating the part from
In The Beginning
Introduction drape forming over male molds and Mid-range 0.060-0.120-in., 60-120
free-blow forming were the common mils, or 1.5-3.00 mm in
The thermoforming cognoscenti
ways of forming heavy-gauge sheet. thickness
among you know that this series has
Vacuum forming into female molds Heavy-gauge Greater than 0.120-in.,
focused on some of the general con-
was the common way of forming thin- 120 mils, or 3.00 mm in
cepts in thermoforming. We began
gauge sheet. thickness
with brief descriptions of polymers,
then discussed heat transfer, mold Plate Greater than 0.500-in.,
materials, heaters, oven design, form- How Big is 500 mils, or 13 mm in
ing temperatures, sheet stretching and thickness
cooling, trimming, and ended with
Thermoforming?
regrind. A complete list of topics ap- In 1960, U.S. thermoforming pro- Keep in mind that “foil” may be
pears at the end of this article. duced about 100 million pounds of used for any thin-gauge sheet in
In truth, the series was to have product. In 2000, that number was ap- Europe. Another way of categoriza-
ended in the last issue. But, after re- proaching 5,000 million pounds. This tion is:
viewing the 18 “lessons,” it became Roll-fed Sheet provided to the
apparent that there were thermoformer in a roll
some monstrous holes,
the most obvious of THERMOFORMING Cut sheet Sheet provided to the
thermoformer on a pal-
which was the lack of 101 let
substantial discussion
on product design. So, This category is useful for determin-
consider the next few ing the type of machine to be used to
articles to be “hole form the products. Another:
pluggers.” is a sustained growth
Packaging Usually considered as
rate of 6% per year over
thin-gauge sheet prod-
forty years. Thermoforming amounts
Just What is to about 5% to 6% of the total U.S.
ucts
Thermoforming? plastics consumption. Conservatively Industrial or Usually considered as
structural heavy- gauge sheet
Thermoforming is the manufacture there are about 500 U.S. heavy-gauge
products
of useful articles of commerce by thermoformers and 125 U.S. thin-
heating, shaping, cooling, and gauge thermoformers. And another:
trimming thermoplastic sheet. Disposable Usually considered as
Is All Thermoforming the thin-gauge sheet prod-
ucts
Where Did It Come From? Same?
Although historians consider the Permanent Usually considered
No. Thermoforming is usually
forming of tortoise shell, tree bark, as heavy-gauge sheet
(loosely) categorized in several ways. products
and horn to be the earliest forms of
Probably the most apparent way
thermoforming, purposeful manufac- And finally one more:
ture of products from semi-manmade is in terms of sheet thickness. Simply
thermoplastic sheet began in the put, thin sheet is provided to the Vacuum Draw-down by evacu-
mid-1800s, with the commercializa- thermoformer as a continuous roll. forming ating the space between
tion of polymerized cellulose nitrate. Thick sheet cannot be rolled and is the sheet and the mold
The production of thermoformed supplied as palletized cut sheet. Thin Pressure Application of air
household items such as hairbrush sheet forming is frequently called thin- forming pressure in excess of one
backs, mirror cases, baby rattles, and gauge forming. Thick sheet forming atmosphere
piano keys was a reasonably large is called heavy-gauge or thick-gauge Be careful of using one of these ways
business by the turn of the twentieth forming.
century. With the invention of Bakelite, as shorthand in formal communication.
Here is one way of categorization: Always define the terms you use to
a completely synthetic thermosetting
polymer in 1909, the emphasis on Foil (very Less than 0.010 in., 10 avoid misinterpretation. For example,
product development moved quickly thin sheet) mils, or 250 microns in even though low-density polystyrene
to compression molding. The commer- thickness foam can range in thickness up to 0.250-
cialization of new thermoplastics such Thin-gauge Less than 0.060-in., 60 inch (250 mils, 6.4 mm), it is delivered
as polystyrene, polymethyl methacry- mils, or 1.5 mm in thick- to the thermoformer in rolls. ■
late (acrylic), and cellulose acetate in ness Keywords: history, categorization,
the 1930s spurred the development of
thin-gauge, heavy-gauge, market size
thermoforming, as did WWII. Then,
Alphabet Soup?
I t seems that plastics people never
tire of their alphabet soup – ABS,
PTFE, PVC, PUR, and on and on. The
Conversely, if we cool water from
room temperature to 32°F (0°C), it
freezes. At the freezing point, the THERMOFORMING
soup continues when we consider temperature remains constant even 101
evaluating the characteristics of plas- though substantial energy is removed
tics. In this short series, we consider a from the water. heat capacity. As we saw above, the
few of the letters in this soup. Physical changes that take up amount of energy absorbed by water
energy with little or no temperature is 1 cal/gm°C or 1 Btu/lb°F. So its heat
Tg, Tm and DSC change, such as boiling or melting, are capacity is 1.0. It takes 100 cal/gm°C or
called endothermic changes. Physi- 180 Btu/lb°F to heat water from 32°F
We’ve already discussed the first cal changes that give off energy with
two. Tg is glass transition tempera- to 212°F. We find that polystyrene has
little or no temperature change, such about 55% of the heat capacity of water
ture, or the temperature above which as freezing or crystallizing, are called
polymers become rubbery rather than and that for PVC has about 37% of that
exothermic changes.
glassy. Tg’s for polystyrene and acrylic of water. PP has about 85% of the heat
We can build a device that compen-
are around 210°F (100°C). Tg for capacity of water and that for LDPE
sates for these temperature differen-
rigid PVC is around 185°F (85°C) but is about the same as that of water.
tials. The device uses a well-charac-
can be as low as -25°F (-30°C) when Remember, now that these values are
terized substance as its reference. The
highly plasticized. The glass transi- between transitions.
substance to be tested is then heated
tion temperature for nylon 6 is only DSC is important when trying to
at the same rate as the reference sub-
122°F (50°C). The Tg for polyethylene determine the extent of crystallization
stance. This is done by carefully con-
is around -125°F (-90°C) and that for of a polymer. Consider the case for a
trolling the energy ratio between the
homopolymer PP is 15°F (-10°C). reference substance and the test sub- 100% crystalline polymer that requires
You’ll recall that Tm is the melting stance. Since the device is measuring 100 cal/g to melt. If that polymer is
temperature for crystalline polymers calories or units of energy, it is called a cooled from the melt and DSC deter-
such as polyethylene, polypropylene calorimeter. Since the device measures mines that only 50 cal/g was liberated
and nylon. The melting temperature the temperature difference between during recrystallization, it is safe to say
for HDPE is around 275°F (135°C). The two substances as they heat, it is a that the polymer at room temperature
melting temperature for homopoly- scanning device. And since the device is only 50% crystalline.
mers PP is 330°F (165°C), and that for is looking at the difference between In the last lesson, we learned that
nylon 6 is 430°F (220°C). the two substances, it is a differential coPP melts around 155°C but recrys-
One popular method for measuring device. It we put this all together we tallizes at around 100°C. How did we
Tg and Tm is with DSC. So, what is see that the device is a differential know that? From DSC, of course.
DSC? Differential scanning calorime- scanning calorimeter, or DSC! The DSC can teach us another as-
try. Consider heating a substance from pect to polymer characterization. As
room temperature, say, to a specific What Can We Learn From we increase the cooling rate for some
processing temperature. Let’s use wa- crystalline polymers, we retard the
DSC? temperature at which recrystalliza-
ter as an example. It takes exactly one
calorie of energy to heat one gram of First, we must realize that the DSC tion begins. And we reduce the final
water one degree Centigrade. In Brit- can be used either in a heating mode or level of crystallinity. How do we know
ish units, it takes one British Thermal in a cooling mode. Samples are usually this? Consider PET. It has a melting
Unit of energy to heat one pound of heated beginning at room temperature temperature of 510°F (265°C). If we
water one degree Fahrenheit. This rule and they are usually heated at a fixed cool PET very slowly, we find that it
works until water reaches its boiling temperature rate such as 10°C/minute. recrystallizes at around 250°C to about
point of 212°F (100°C). At the boiling The temperature range and energy 40-45%. If we cool PET very rapidly,
point, the temperature remains con- requirements of transitions are the we find that there is no recrystalliza-
stant even though substantial energy primary information gathered from tion region. PET remains amorphous
is inputted to the water. If we were heating DSCs. The most common at room temperature and beyond. DSC
to compare the energy uptake of a transitions are the glass transition is therefore a tool for determining how
substance that did not boil with that temperature and the melting tempera- rapidly a plastic crystallizes. ■
of water, we would see that the tem- ture, if any.
Keywords: glass transition, melting,
perature of the non-boiling substance Between transitions, the DSC pro-
recrystallization, calorimeter,
would continue to climb while that of vides relative energy uptake by the
endothermic, exothermic
water would remain constant until all test substance. This is directly related
the water had evaporated. to that for water, as specific heat or
Draft Angles
S ome time ago, we discussed
shrinkage and warpage. At that
time, we pointed out that plastic, like
the mold surface. To release the part
from the mold, it is necessary to
provide a draft angle on the vertical THERMOFORMING
most other materials, increases in mold surfaces. The amount of draft 101
volume when heated and decreases depends strongly on the volumetric
in volume when cooled. And we change in the polymer. If the polymer
said that to form the desired shape, is amorphous – PS, PVC, PC – the
the hot plastic is pushed against a draft angle may be no more than
cool mold surface. It follows that as 2° to 3°. If the polymer is crystalline
– PE, PE – the draft angle may be in segments may also be sources of
the plastic cools, it shrinks. But the
excess of 5°. The average is generally internal webbing3.
mold doesn’t change in dimension.
If the mold is male or positive, or if 4° but the designer must be alert to
even a portion of the mold is male or effects of temperature variation and How Serious is the Draft
recrystallization rates.
positive, the plastic will shrink onto
A textured surface requires
Problem?
the mold surface. And if the mold is
not properly designed, we will have an increase in draft angle. It is The draft angle can lead to serious
a devil of a time getting the part off recommended that the draft angle be dimensional changes in the formed
it. Thus we face the subject of draft increased at least 1° for every 0.2 mils part. Consider a simple example, a
angles. [0.0002 in or 5 microns] in texture 10-inch male mold. The vertical wall
depth. Keep in mind that increasing is 1 inch wide at the top. Consider
applied pressure, sheet temperature, a draft angle of 5°. The width at
Draft Angles – Defined and mold temperature will result in the bottom of the vertical wall is
The best definition of a draft angle greater penetration of the sheet into determined as follows:
is the angle the mold wall makes the texture. The increased width on one side is
with the vertical. If the mold wall is 10 x tan 5° = 0.875 in. The total width
vertical, the draft angle is zero. Recall What About Parts at the bottom is then 1 + 2 x 0.875 =
that most thermoforming molds are 2.75 in.
single-surfaced. That is, the sheet
With Male and Female This is a substantial dimensional
is pulled into or over a single mold Components? change in the thickness of the vertical
surface. For draw-down into a wall.
Multiple-compartment trays and
female or negative mold, the sheet pallets 1 can pose series drafting
is constrained on its outer surface issues. Consider a female cavity When is the Draft Angle Not a
by the mold. As a result, when the bordered by two male segments. The Draft Angle at All?
sheet cools, it tends to shrink away sheet will attempt to shrink away
from the mold surface. As a result, When it is used for something
from the female mold surface but else. The classic example is the drink
it is entirely feasible to thermoform onto the male segments. Excessive
into a female mold having zero draft cup. The sidewalls are tapered as
draft on the male segments may much as 20° for stacking purposes,
angles. Most part designers prefer a allow the sheet to release from the
slight draft angle, say 0° to 2°, “just not shrinkage. In multi-compart-
female mold surface before the sheet ment parts, care must be taken in
in case.” The average is generally has replicated the mold surface. On
1/2° to 1°. the design to accommodate both the
the other hand, inadequate draft draft angle required for shrinkage
On the other hand, when the sheet on the male segments may allow
is drawn over a male or positive mold, and the necessary stacking taper.
the sheet to satisfactorily form the
it is constrained on its inner surface Stacking lugs, stand-offs, or rings
female mold surface, but the sheet
by the mold. As a result, when the are often designed into complex
may “lock” onto the male segments.
sheet cools, it tends to shrink onto parts, simply because it is not always
The problem is exacerbated2 when
possible to predict the exact local
1
These parts are sometimes called an- molding compartment trays where
shrinkage. ■
drogynous, meaning that they have both the male portions are interrupted.
female and male characteristics. Essentially interrupted walls in
Keywords: draft angle, taper,
2
Exacerbate: To aggravate. the molded part. In addition to the
shrinkage
3
Webbing will be discussed in a later shrinkage issues, interrupted male
lesson.
CORNERS
M ost plastic parts have corners.
And most corners are radiused.
Designers often seek sharp corners or
We must keep in mind that the
plastic stretches from the sheet that
is not contacting the mold surface. As
more properly, corners with very more and more of the plastic sheet THERMOFORMING
small radii. Aesthetics is often cited contact the mold surface, the sheet 101
as the reason for this. But aesthetics not contacting the mold becomes
is not the only reason. Often the thinner and thinner. For a part such
container must contain material as a cup or can, the plastic stretches
of a specific volume. For a given into the bottom 2D corner last. As
dimensioned container, the internal a result, the material in the corner
volume decreases with increasing is usually the thinnest. Although
mechanical and pneu-matic assists radius in one corner of the part that
corner radii. Con-versely, for a given
help redistribute the sheet during is 50% of that in another corner of the
volume, the overall dimensions of
stretching, the part wall is usually part, the part thickness in that corner
the container (and thus the amount of
thin in the corners. And smaller will have 50% of the thickness in the
plastic needed to make the container) corner radii usually lead to thinner
increase with increasing corner other corner. If the corner design
part walls. In other words, sharp radius is 25%, the part thickness will
radii. In this lesson, we consider the corners lead to thin-walled parts in be 25% of that in the other corner.
concept of the corner. corners. Why are we concerned about
part wall thickness in 3D corners?
Can a Part Have More Wall Thickness in Because many of our parts are similar
Than One Type of Corner? 2D Corners to the five-sided box we’ve used as
an example. And five-sided boxes
Of course. Consider the simplest The wall thickness in the bottom are often filled and handled during
type of corner, being the place where 2D corner of a five-sided box is shipping, installation, and use. And
two planes intersect. Picture the proportional to the corner radius to 3D corners of five-sided boxes are
bottom edge of an axisymmetric part about the 0.4-power. If the design most susceptible to impacting. In
as a drink cup or a can, for instance. calls for a radius in one area of the an earlier lesson we discussed that
The vertical or near-vertical side of bottom of the part that is 50% of that when we stretched a sheet, we
the container intersects the bottom of in another area of the bottom of the thinned it. We needed greater forces
the container at a right or near-right part, the part thickness in that area to stretch the sheet to greater and
angle, thus forming the corner, in will have about 75% of the thickness greater extent. And when we cooled
this case, a bottom two-dimensional of the other area. If the design radius the sheet we locked in the stresses
or 2D corner. Of course, any good is 25%, the thickness in that area will we used to stretch the sheet. So
thermoformer worth his or her be about 55% of that of the other when we impact the 3D corner of
salt would not make a sharp angle area. the formed part, we are applying
at the intersection. The reason for I n t e re s t i n g l y e n o u g h , w a l l stress on top of those already frozen
this is intuitively obvious but will thickness in vertical 2D corners is into the corner. On top of this, the 3D
about equal to wall thickness of corner is very thin. In short, sharply-
be explained in a little more detail
surfaces adjacent to the corners. This radiused corners are often desired
later.
is probably because the part walls by designers but of great concern
Is there more than one type of
in the vertical corners are formed to thermoformers. As a result, the
corner on a five-sided box? Sure. at the same time the part walls of designer must often accept greater
There’s the intersection between adjacent surfaces are formed and not radiuses than he/she desires.
the vertical wall and the bottom. afterwards, as is the case with bottom In a subsequent lesson, we consider
And the intersection between one 2D corners. alternative designs for corners, as
vertical wall and another. And what well as other product features. ■
about the intersection between two
vertical walls and the bottom? So we
Wall Thickness in
Keywords: vertical 2D corner,
have bottom two-dimensional or 2D 3D Corners
bottom 2D corner, 3D corner,
corners, vertical 2D corners, and in The wall thickness in the 3D corner corner radius
the last case, three-dimensional or 3D of a five-sided box decreases in
corners. And, as with the cup or can proportion to the corner radius to the
example, corners should have radii. 1.0-power. If a design calls for a 3D
The Rim
S o, we know about draft angles
and corners and wall thickness
variation and on and on. But
chamfers, and ridges. The rim
may be designed to fit
into or over another THERMOFORMING
what about the rim? You know, part, Or it may be 101
the region of the formed part that trimmed to accept
forms the periphery of the part. secondary assembly
This lesson focuses on some of the features. The part
important issues dealing with the design may require
rim. In the next lesson, we’ll look at the trim line to
the characteristics of the trimmed be “hidden,” so that the rim is portion of the part. And keep in
edge itself. U-shaped with appropriate radii mind that, without plug assist,
or chamfers. parts really thin rapidly when
Does the Rim Have a vacuum- or pressure-drawn into
The Impossible
Draw Ratio
A Technical Article – 2006 Volume 26, #3
➤ By Barry Shepherd
(Technical Editor’s Note: Looking back over the last 9 years at 36 too expensive. The designer must make a decision knowing
Thermoforming 101 articles, which are all presented in our annu- that he has a number of tooling options available.
ally updated booklet, it is the most comprehensive collection of
basic technical information one could find on our process. For this Pre-Stretch Tooling
issue I have chosen to talk about a subject that my predecessor Jim
Throne wrote about in 2000 and 2001 – pre-stretching the sheet. The main problems that must be addressed in designing
But this time I want to discuss what type of pre-stretching should the tooling for this part is a) how to pre-stretch the mate-
be used in a very difficult application.) rial so that there is enough material in the areas around
the towers and b) how to get the material down into the
valleys between the towers without webbing or bridging.
Knowing It Can Be Done
Pre-stretching the material can be done by forming a seal
The customer knows what he wants and you want to give on the material around the edge of a box and drawing
him a part that will do what he wants but in the back of a vacuum to pull the sheet into a bubble. This is called a
your mind you are thinking, “I should be telling him this pre-draw box and this is done on the opposite platen to
is impossible.” However, you know it is possible with the the mold platen. So now we have stretched the material
right tooling. to give us enough surface area to cover the towers with-
The main ingredient in getting hot plastic to form tight out getting too thin. Now how do we get all that material
over a mold is vacuum. Air pressure and other various down to the bottom of the valleys?
forms of assist tools make vacuum forming, thermoform-
ing. The trick is to decide what tooling options to use to Plugging or Pushing
give the customer what he wants without creating prob- This is where a newer technique of plug assist can be used
lems for your production department, while staying within effectively. Visualize the material in a bubble hanging
the customers tooling budget. below the mold in the clamp frames. It has been pulled
Back in the days when we used to say thermoforming is down by the pre-draw box. With an independently acting
half art, half science we would make a mold, put it into the air cylinder inside the pre-draw box, a plug or pusher tool
press and see what happens. Then start adding pieces of can be mounted and used to push the pre-stretched mate-
wood we called web stretchers and if we had a top press rial into the valleys. Obviously you must have this capability
at that time we could build a pusher to assist the plastic built into your machine and the timing must be such that
into a problem area. OK, so maybe some of us still do this the mold, vacuum and pusher are activated in the right
in prototyping but the ultimate aim for all of us is to build sequence.
production tooling that will go into the machine and start If the machine does not have the capability to have this
forming good parts on the first shot. third motion tool then it may be possible to mount a fixed
pusher inside the pre-draw box. However this means the
Part Design/Tool Design material must then drape around the pusher during the
You can’t design a thermoformed part unless you have a pre-stretching and this could mean that the material cools
full understanding of tool design and what capabilities you in these areas causing other forming problems. Pusher
have in your equipment. This seems obvious but when the shape and heating then becomes critical.
part has extreme draw ratios and wall thickness require-
ments that must be met, it is imperative. Impossible No More
Let’s take a heavy gauge part that has towers that defy We see thermoformed parts now that once would be im-
all principles of thermoforming, 8” high, only about 2” possible to thermoform – especially in roll-fed, thin gauge
diameter at the top and only 6” between towers and it applications. Third motion tooling, improved materials and
must be polyethylene which makes matters worse. The plug assist design has made severe draw ratio’s common
configuration of the part is such that the tall sections are at place in the packaging and drinking cup sector. The same
the perimeter. In other words, this is a job that would seem principals can be used in heavy gauge, sheet-fed thermo-
impossible. But the customer is faced with having to build forming to form large heavy parts. ➤
these parts on a limited budget and other processes are