Khalifa University of Science, Technology and

Research

Mechanical Engineering Department

Principles of Manufacturing Lab[MECH 470]
Fall 2013
Laboratory Experiment No. 9

Thermoforming
Student IDs:
MajedAlshehhi

100035560

Yousif Al Hosani

100035400

Ahmad Alkhuroosi

100033713

Reported to: Dr. Bashar El-Khasawneh

Revised by: Mr. Prabu Raja

Experiment Date: 10/12/ 2013

Objectives
To understand the process of the following operations (Thermoforming):
1. Vacuum Forming
2. Plastic Dip coating
3. Extrusion
4. Plastic Welding

Theory
Thermoforming is a process in which a flat thermoplastic sheet is heated and deformed
into the desired shape. The process is widely used in packaging of consumer products and
to fabricate large items such as bathtubs, contoured skylights, and internal door liners for
refrigerators.
Thermoforming consists of two main steps: heating and forming. Heating is usually
accomplished by radiant electric heaters, located on one or both sides of the starting
plastic sheet at a distance of roughly 125 mm. Duration of the heating cycle needed to
sufficiently soften the sheet depends on the polymer, its thickness and color. The methods
by which the forming step is accomplished can be classified into three basic categories:
(1) vacuum thermoforming, (2) pressure thermoforming, and (3) mechanical
thermoforming.

Vacuum Thermoforming
The earliest method was vacuum thermoforming (called simply vacuum forming when it
was developed in the 1950s), in which negative pressure is used to draw a preheated sheet
into a mold cavity. The process is explained below in its most basic form. The holes for
drawing the vacuum in the mold are on the order of 0.8 mm (0.031 in.) in diameter, so
their effect on the plastic surface is minor.
Vacuum thermoforming: (1) a flat plastic sheet is softened by heating; (2) the softened
sheet is placed over a concave mold cavity; (3) a vacuum draws the sheet into the cavity;

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and (4) the plastic hardens on contact with the cold mold surface, and the part is removed
and subsequently trimmed from the web.

Plastic Dip Coating

Plastic dip coating is an industrial process in which a protective plastic coating is used to
sheathe and cover a finished product. A variety of products are subjected to plastic dip
coating before production is completed.
The main function of plastic dip coating is to protect a product and increase the length of
its shelf life, although plastic dip coating can also be used for decorative reasons.
Additionally, the plastic coating can be used as a means of insulating electrical wiring for
safety reasons.
Plastic dip coating is often used to coat metallic products like electrical wiring and wire
hangers. In addition to preventing rust by protecting the metal from exposure to the open
air, plastic dip coating also prevents the metal from soiling anything that it comes in
contact with. This is especially useful with wire hangers, as the coating can prevent
clothes from becoming stained.
The process of plastic dip coating is achieved by immersing an object in hot liquid
plastic. The object is then removed from the plastic at a constant rate to prevent
irregularities from forming on the surface. The faster the object is removed, the thicker
the plastic coating.

Extrusion Thermoforming
This process is often called in-line thermoforming. It is thermoforming, but in the
present case the thermoforming unit is attached to the extrusion unit, and all is done in
one-step. The thermoforming unit is fed by the sheets coming directly from the die,
without any winding.

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This processing technology involves putting a thermoformer behind an extrusion line to

go from pellets to finished product in one operation. This was originally done to produce
vending cups, because the product was always of the same type, and the line would run
for days.

Plastic Welding

The joining together of two pieces of material, through the fusion of a third piece such as
a filler or rod. Hot air, ultrasonic, vibration, spin and hot plate technologies have all been
developed for thermoplastics. Like metal welding, the two pieces being welded have to
be the same material, as does any filler (so that everything melts at the same
temperature).

Experimental Apparatus and Procedure

1. Create a Hammer part using any CAD program, we used Solidworks.
2. Save the file as .stp.
3. Import the file in MasterCam.
4. Make the proper adjustments for the size.
5. Choose Surface Rough for the toolpath.
6. Choose the tool and enter the values for the feed rate and spindle speed, etc.
7. Choose Surface finish to fix the sharp edges.
8. Choose the tool and enter the values for the feed rate and spindle speed, etc.
9. Verify the operations and check the simulator for any errors and the operation
time.
10. Export the .MDF file to be used by the CNC machine.
11. Import the .MDF file in the CNC and adjust the axis.
12. Start the milling operation.
13. The resulted part is our mold to be used in the Vacuum Forming.
14. Place the mold on the platen and Raise the clamp frame on the Vacuum Forming
Plate.
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15. Place a thermoplastic sheet over the aperture and lower the clamp frame and
clamp it with the toggle clamp to secure the sheet.
16. Set the Timer, Move the Heater from the Oven position to the Vacuum Forming
Plate, and Start the timer.
17. When the timing cycle is complete, cancel it and start the vacuum pump.
18. Move the heater back into the Oven position and raise the platen.
19. The shape of the mold is now adopted by the sheet as the air is evacuated from the
platen.
20. Once the platen is fully evacuated and the material has begun to cool, turn the
PSS to Vacuum Forming Blow to start releasing the forming from the mold.
21. Once the forming has been released from the mold, lower the platen.

Results of Experiment

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Discussion and Interpretation of Results

We faced a difficulty in importing the part to the MasterCam. The first problem was to
center the part in the coordinate system in the .stl file, but it was solved by saving the part
in .stp format. The other problems were small and most of them regarding the program,
but Mr. Prabu helped us to solve them.
Conclusion

Through this experiment, we were able to understand how the vacuum forming process is
performed. Also, we learned how to design a part and form it using the CNC machine
which is very important in our studies.

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