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Thermoforming Mold Comparison: Temperature vs. Non -Temperature Controlled Molds

Aaron Lapinski. Thermoforming Mold Comparison: Temperature vs. Non -Temperature Controlled Molds. Purpose. To prove to Industry that using a temperature controlled mold helps improve cycle consistency and part dimensions. Goals.

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Thermoforming Mold Comparison: Temperature vs. Non -Temperature Controlled Molds

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  1. Aaron Lapinski Thermoforming Mold Comparison: Temperature vs. Non -Temperature Controlled Molds

  2. Purpose • To prove to Industry that using a temperature controlled mold helps improve cycle consistency and part dimensions

  3. Goals • To determine how a temperature controlled aluminum mold and non-temperature controlled Ren Shape mold of the same dimensions will affect shrinkage of a thermoformed ABS part. • To gain experience on the set up and operation of the industrial scale MAAC thermoformer • To develop a thermoforming lab experiment on the MAAC thermoformer for student education in Pennsylvania College of Technology’s BPS program. • To demonstrate to the thermoforming industry that a temperature controlled mold is essential for maintaining consistency in the finished product.

  4. Equipment • MAAC Thermoformer • REN Mold • Aluminum temperature controlled mold • Circulator • Sterlco VISION 4410-C • 250°F max temp

  5. Material • Spartech ABS • Amorphous Terpolymer • .125 x 40 (W) x 22.5 (L) inches • Premium Grade • Natural • Polished Finish

  6. Optimum Settings • Sheet temperature 285-400of • 340oF • Circulator settings 175-215oF • 200oF • De-molding temperature • 180-190oF

  7. Procedure • Dry ABS • 180°F • 24 hours • Hang the Mold • Placement • Center • Form parts • Collect Dimensions • Perform Mechanical Testing

  8. Operating the MAAC • Turn on Main Power • Turn on Air • Turn on Vacuum • Turn on Fume Hood • Enter MAAC software PC62 • Log in • Load or Build Program • Choose set up • Turn on Vacuum Pumps and Oven • Index Clamps into Oven on Diagnostics screen

  9. Operating the MAAC Continued • Remove preheated clamps from oven • Open clamps • Place sheet • Start cycle

  10. Trials • Ren Shape Mold Production Trial • Aluminum Mold Production Trial • DOE

  11. REN Mold Process settings • Timers • Ovens • Encoders • I.R. Eye • MAACFlex

  12. Aluminum Mold Process Settings • 380°F • 55 Second Forming Time

  13. Thermal Conductivity • Aluminum Mold • 144.447 Btu (IT) foot/hour/square foot/°F • Ren Shape or Polyurethane • 0.011556Btu (IT) foot/hour/square foot/°F.

  14. Temperatures • Humidity • Room Temperature • Mold Temperatures • Front • Back • Top • Clamp Temperature • Sheet Temperature • De-molding • Molding

  15. Measurements

  16. REN Part Width vs. Aluminum Part Width

  17. REN Part Length vs. Aluminum Part Length

  18. Thickness

  19. REN Mold

  20. Aluminum Mold Temperature

  21. DOE

  22. Testing Equipment

  23. Testing Results

  24. Defects • Holes • Stuck to mold

  25. Project Cost

  26. Benefits • More Predictable dimensions • Higher mechanical properties • Shorter cycle times • Forming time from 100 to 55 seconds

  27. Cost Savings

  28. Obstacles • Lack of Knowledge • Measurement Device • Drying • Grids • Mold Position • Circulator • Machine access

  29. Individual Performance Objectives • To determine how a temperature controlled aluminum mold and non-temperature controlled Ren Shape mold of the same dimensions will affect shrinkage of a thermoformed ABS part. • To gain experience on the set up and operation of the industrial scale MAAC thermoformer • To develop a thermoforming lab experiment on the MAAC thermoformer for student education in Pennsylvania College of Technology’s BPS program. • To demonstrate to the thermoforming industry that a temperature controlled mold is essential for maintaining consistency in the finished product.

  30. Acknowledgements • Mr. Roger Kipp • Mr. John Bartolomucci • Mr. Gary McQuay • Mr. Howard Troup • Mr. Todd Kennedy • Mr. Todd Crismer • Mr. Brett Braker • Mr. Chris Denmon • McClarin Plastics Inc. • Spartech Plastics • Tooling Technology • KYDEX LLC.

  31. References • "Acrylonitrile, Butadiene and Styrene (ABS) - FormTight Plastic Thermoforming." Custom Packaging - Clamshells, Food Packaging, Blister Packaging - FormTight Plastic Thermoforming. Web. 27 Oct. 2010. <http://www.formtightinc.com/materials/ABS/default.html>. • "Acrylonitrile Butadiene Styrene." Wikipedia, the Free Encyclopedia. Web. 27 Oct. 2010. <http://en.wikipedia.org/wiki/Acrylonitrile_butadiene_styrene>. • "Acrylonitrile-butadiene-styrene Copolymer (ABS) (chemical Compound) -- Britannica Online Encyclopedia." Encyclopedia - Britannica Online Encyclopedia. Web. 27 Oct. 2010. <http://www.britannica.com/EBchecked/topic/4259/acrylonitrile-butadiene-styrene-copolymer>. • "ASTM D638 - 10 Standard Test Method for Tensile Properties of Plastics." ASTM International - Standards Worldwide. Web. 24 Apr. 2011. <http://www.astm.org/Standards/D638.htm>.

  32. Questions?

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