THERMOFORMING MANUAL and TROUBLE-SHOOTING GUIDE

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A Guide to Thermoforming

THERMOFORMING AND TROUBLESHOOTING GUIDE

THERMOFORMING AND TROUBLESHOOTING GUIDE

VACUUM FORMING GUIDE

courtesy of Leroy M. Boser 574-370-2003

Table of Contents

PREFACE…………………………………………………………………………………..1
DESCRIPTION OF VACUUM FORMING………………………………………………1
VACUUM FORMING TECHNIQUES …………………………………………………..1
1. DRAPE FORMING – BOTTOM (Figure 1.) ………………………………………….1
2. DRAPE FORMING – TOP ……………………………………………………………..4
3. PLUG ASSIST – BOTTOM (Figure 2.)………………………………………………4
4. PLUG ASSIST – TOP ………………………………………………………………….6
5. SNAP BACK – TOP See figure 3. ……………………………………………………7
6. SNAP BACK – BOTTOM See figure 3……………………………………………….9
7. BILLOW FORMING – FEMALE (BOTTOM) See figure 4. ……………………….10
8. BILLOW FORMING – FEMALE (TOP)……………………………………………..12
9. BILLOW FORMING – MALE (BOTTOM)…………………………………………..12
10. BILLOW FORMING – MALE (TOP) ………………………………………………13
11. ZERO GRAVITY …………………………………………………………………….13
12. PREBLOW PLUG ASSIST FORMING…………………………………………….15
13. TWIN SHEET FORMING (Figure 4.1) ……………………………………. ……15
14. MATCHED-MOLD THERMOFORMING (Figure 4.2)………………………….18
15. FREE FORMING OR BUBBLE FORMING……………………………………….18
16. HAND FORMING…………………………………………………………………..20
DRAW RATIOS………………………………………………………………………….21
IMPORTANT CONCERNS IN VACUUM FORMING………………………………..26

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Let’s compare Thermoforming Techniques

Lets compare Thermoforming techniques

  • Vacuum forming - A vacuum is formed between the mold cavity and the thermoplastic sheet. The vacuum pressure (typically 14 psi) forces the sheet to conform to the mold and form the part shape.

    Thermoforming - Vacuum Forming
    Vacuum Forming

  • Pressure forming - In addition to utilizing a vacuum underneath the sheet, air pressure (typically 50 psi, but up to 100 psi) is applied on the back side of the sheet to help force it onto the mold. This additional force allows the forming of thicker sheets and creating finer details, textures, undercuts, and sharp corners.

    Thermoforming - Pressure Forming
    Pressure Forming

  • Mechanical forming - The thermoplastic sheet is mechanically forced into or around the mold by direct contact. Typically, a core plug will push the sheet into the mold cavity and force it into the desired shape.

    Thermoforming - Mechanical Forming
    Mechanical Forming


What is thermoforming? The Video, a video guide to thermoformers

Courtesy of the SPE Thermoforming Divisions, a video guide to thermoformers

Do you know what blister packaging is?

Do you know what blister packaging is?

Blister packaging

is a term  used to package  several types of pre-formed thermoformed plastic parts for consumer goods, and for pharmaceuticals.

The primary component is a  blister  which is a thermoformed  part which is then adhered to a pre printed board or a lidding material such as tyvek..

The plastic thermoformed blister is dropped into the blister sealer so it will fit tightly into a  heat sealing tray where the product to be packaged is placed in the heat sealer

A preprinted card is placed on top of the blister and then indexed into the heat sealer ; The blister is affixed to the card using heat and pressure to activate an adhesive (heat seal coating) on the blister card. The adhesive is strong enough so that the pack may hang on a peg, but weak enough so  that the package can be easily opened.

Medical Blister applications use a  lidding film  that provides a peel-open feature and is generally porous to allow sterilization (Tyvek material). These medical blister packs are used for medical devices, used in hospitals.

Thermoforming

Thermoforming is when a plastic film or sheet heated by an oven. A blister  is formed when the hot sheet goes over the  blister cavity mold, vacuum is turned on and a thermoformed part is formed… The mold is cooled  and the plastic sheet takes the shape of the mold. The finished part is then trimmed into individual pieces or blisters and then  placed in a heat sealing machine .to produce a packaged product.

 Blister Sealing Machines

 sencorp HP12                    blister sealer                            rotary blister sealer                                      tray blister sealer

 

Blister Sealers-New and Used

Various blister sealing machines, production and table top.  These  standard, blister sealing machines are adaptable to specific blister sealing applications depending on the volume of parts you wish to produce. There are a variety of heat seal press platen sizes, as well as shuttle and rotary blister sealing machines that you can choose from. All the blister sealing machines have safety features build in such as low pressure safety descent with high pressure seal. Manufacturers of blister sealing machine are Alloyd, Algus, Atlas Vac,  Starview Packaging,

Visual Packaging, Sencorp Belco, and Zed. This type of equipment can be purchased new or used.  Additional information is available through Plastimach Corp   www.plastimach.com.

LYLE INDUSTRIES LINE THERMOFORMING PET BERRY BASKETS

LYLE INDUSTRIES LINE THERMOFORMING PET BERRY BASKETS