{"id":1586,"date":"2020-07-14T17:39:34","date_gmt":"2020-07-14T15:39:34","guid":{"rendered":"https:\/\/www.2milasrl.it\/?p=1586"},"modified":"2021-03-17T16:49:39","modified_gmt":"2021-03-17T15:49:39","slug":"conversion-technologies-plastics-thermoforming","status":"publish","type":"post","link":"https:\/\/www.2milasrl.it\/en\/conversion-technologies-plastics-thermoforming\/","title":{"rendered":"CONVERSION TECHNOLOGIES FOR PLASTICS &#8211; 5: THERMOFORMING"},"content":{"rendered":"<p class=\"p1\"><span class=\"s1\">In this information document, the last in the <b>Conversion Technologies series<\/b>, we shall talk about a technique that is perhaps the simplest and most ancient in the<span class=\"Apple-converted-space\">\u00a0 <\/span>thermoplastic polymers conversion panorama and, in some respects, the most fascinating. <\/span><\/p>\n<p class=\"p1\"><span class=\"s1\">We are talking about <b>thermoforming<\/b>. <\/span><\/p>\n<p class=\"p2\"><span class=\"s1\">It is issued as the last one because it is a technique that starts from afar, from the extrusion of a plate<i> (see <a href=\"https:\/\/www.2milasrl.it\/en\/conversion-technologies-plastics-injection-molding\/\">issue 1<\/a>) <\/i><\/span><span class=\"s1\">and uses two additional media: the mold and the air. Elements in common to other techniques of which we have already spoken in this \u201cShared Knowledge\u201d work <i>(see <a href=\"https:\/\/www.2milasrl.it\/en\/conversion-technologies-plastics-injection-blow-molding\/\">issues 2<\/a>, <\/i><\/span><span class=\"s1\"><i><a href=\"https:\/\/www.2milasrl.it\/en\/conversion-technologies-extrusion\/\">3<\/a>\u00a0<\/i><\/span><span class=\"s1\"><i>and <a href=\"https:\/\/www.2milasrl.it\/en\/conversion-technologies-extrusion-blow-molding\/\">4<\/a>).<\/i><\/span><\/p>\n<p class=\"p1\"><span class=\"s1\">In this particular case the passage from a raw material to a finished object starts from a &#8220;semi-finished&#8221; product.<br \/>\n<\/span><span class=\"s1\">This means, a product that upstream is ready for use as such. It comes in the form of a flat sheet, a shape capable of performing functions as it is <i>(see transparent PPMA flat shields, or for surface decoration or protection)<\/i> contrary to the base raw materials in granulate form of the other technologies we met. <\/span><\/p>\n<p class=\"p1\"><span class=\"s1\">With this technique we accomplish a change of shape, from bi-dimensional to three-dimensional.<\/span><\/p>\n<p class=\"p1\"><span class=\"s1\">We are talking about a process which, although it can be automated, requires a certain manual labor according to the shapes and the dimensions of the pieces to be produced.<br \/>\n<\/span><span class=\"s1\">It is possible to create objects whose dimensional limit in width is given by the extruded sheet which, as we have already highlighted (<a href=\"https:\/\/www.2milasrl.it\/en\/conversion-technologies-plastics-injection-molding\/\">C.C n\u00b0 1<\/a>) can reach 2.0 &#8211; 2.5 meters. <\/span><\/p>\n<p class=\"p1\"><span class=\"s1\">The length in extrusion, as we know, is not a limit.<br \/>\n<\/span><span class=\"s1\">The limit is given by the thermoforming machine and the handling of the finished part.<\/span><\/p>\n<h3 class=\"p2\"><span class=\"s1 text-orange font-400\">What can be done with this technology?<\/span><\/h3>\n<p>Thermoformed products are used today in a very wide field:<\/p>\n<ul class=\"fa-ul\">\n<li class=\"p2\"><span class=\"s1\"><span class=\"fa-li\"><i class=\"fas fa-arrow-right text-orange\" style=\"\"><\/i><\/span>Containers of various shapes, sizes and depths<br \/>\n<\/span><\/li>\n<li class=\"p2\"><span class=\"s1\"><span class=\"fa-li\"><i class=\"fas fa-arrow-right text-orange\" style=\"\"><\/i><\/span>Components for internal and external parts of vehicles<br \/>\n<\/span><\/li>\n<li class=\"p2\"><span class=\"s1\"><span class=\"fa-li\"><i class=\"fas fa-arrow-right text-orange\" style=\"\"><\/i><\/span>External car accessories<br \/>\n<\/span><\/li>\n<li class=\"p2\"><span class=\"s1\"><span class=\"fa-li\"><i class=\"fas fa-arrow-right text-orange\" style=\"\"><\/i><\/span>Interior of refrigerators<br \/>\n<\/span><\/li>\n<li class=\"p2\"><span class=\"s1\"><span class=\"fa-li\"><i class=\"fas fa-arrow-right text-orange\" style=\"\"><\/i><\/span>Shower cubicles and bathtubs<br \/>\n<\/span><\/li>\n<li class=\"p2\"><span class=\"s1\"><span class=\"fa-li\"><i class=\"fas fa-arrow-right text-orange\" style=\"\"><\/i><\/span>Body parts of agricultural machinery<br \/>\n<\/span><\/li>\n<li class=\"p2\"><span class=\"s1\"><span class=\"fa-li\"><i class=\"fas fa-arrow-right text-orange\" style=\"\"><\/i><\/span>Disposable cups and plates<\/span><\/li>\n<\/ul>\n<p class=\"p1\"><span class=\"s1\">The materials used are 80% Amorphous and of these, a large part are made up of PC, ABS, HIPS resins, etc&#8230;<br \/>\n<\/span><\/p>\n<p class=\"p1\"><span class=\"s1\">The pressures and temperatures used are quite low compared to other conversion methods that we have already presented (e.g., injection, extrusion).\u00a0<\/span><\/p>\n<p>&nbsp;<\/p>\n<h2 class=\"p1\"><span class=\"s1 text-orange font-400\">The process <\/span><\/h2>\n<p class=\"p1\"><span class=\"s1\">In summary, the process is based on six standard steps: <\/span><\/p>\n<ol>\n<li class=\"p1\"><span class=\"s1\">loading of the semi-finished product, <\/span><\/li>\n<li class=\"p1\"><span class=\"s1\">heating, <\/span><\/li>\n<li class=\"p1\"><span class=\"s1\">forming, <\/span><\/li>\n<li class=\"p1\"><span class=\"s1\">cooling of the part, <\/span><\/li>\n<li class=\"p1\"><span class=\"s1\">extraction of the part, <\/span><\/li>\n<li class=\"p1\"><span class=\"s1\">finishing the perimeter and the part.<\/span><\/li>\n<\/ol>\n<p><span class=\"s1 text-blue\"><b>1)<\/b> <\/span><span class=\"s1\">The semi-finished product, made of thermoplastic material can be used in the form of:<\/span><\/p>\n<ul>\n<li class=\"p2\"><span class=\"s1\">film (thin film): thickness up to 0.2 mm<br \/>\n<\/span><\/li>\n<li class=\"p2\"><span class=\"s1\">thin or thick film: thickness between 0.2 mm and 2 mm<br \/>\n<\/span><\/li>\n<li class=\"p2\"><span class=\"s1\">sheet: thicknesses greater than 2 mm up to over 10 mm<\/span><\/li>\n<\/ul>\n<p class=\"p2\"><span class=\"s1\"><b><span class=\"text-blue\">2)<\/span> <\/b>The semi-finished product is positioned on a suitable frame in the machine and is blocked along the perimeter by a mechanical jaw fixing systems. <\/span><\/p>\n<p class=\"p2\"><span class=\"s1\">The positioning of the sheet can be done manually or by means of an automatic dragging system, or with a robotized system equipped with vacuum suction cups, as happens with glass sheets.<\/span><\/p>\n<p class=\"p2\"><span class=\"s1\"><span class=\"text-blue\"><b>3)<\/b> <\/span>The two sides of the surface are heated homogeneously, or in a differentiated distribution, with various techniques:<\/span><\/p>\n<ul>\n<li class=\"p2\"><span class=\"s1\">electrically heating resistors,<br \/>\n<\/span><\/li>\n<li class=\"p2\"><span class=\"s1\">infrared elements, or<br \/>\n<\/span><\/li>\n<li class=\"p2\"><span class=\"s1\">heated plates directly in contact with the material.<\/span><\/li>\n<\/ul>\n<p class=\"p1\"><span class=\"s1\"><span class=\"text-blue\"><b>4)<\/b> <\/span>Once the typical softening temperature of the selected polymer is reached (generally from 140 \u00b0 C to 240 \u00b0 C), the sheet is brought to adhere to the mold by the action of the vacuum created by small air evacuation holes created in the tool. <\/span><\/p>\n<p class=\"p1\"><span class=\"s1\">Sometimes it may be necessary to use a punch that &#8220;pre-stretches&#8221; the sheet in order to deform it where it is most needed and thus make the action of the vacuum easier. <\/span><\/p>\n<p class=\"p1\"><span class=\"s1\">Sometimes the pre-stretch can be obtained through air pressure which, by giving a curvature to the sheet, increases its surface favoring the subsequent phase of true forming.<\/span><\/p>\n<p class=\"p1\"><span class=\"s1\"><b><span class=\"text-blue\">5)<\/span> <\/b>After a temporary cooling period, the piece that has become solid can be handled, released from the mold manually or automatically and subjected to further finishing processing.<\/span><\/p>\n<p class=\"p1\"><span class=\"s1\"><span class=\"text-blue\"><b>6)<\/b> <\/span>The perimeter \u201cwaste\u201d remains unscathed from the forming phase, therefore still with the original thickness of the sheet or film. <\/span><\/p>\n<p class=\"p1\"><span class=\"s1\">It is mechanically removed from the piece by hand or automatically and set aside to be recycled and returned to production without difficulty. <\/span><\/p>\n<p class=\"p1\"><span class=\"s1\">Or it can be sold to recycling companies, who are happy with it on account to the high residual quality of the material.<\/span><\/p>\n<p class=\"p1\"><span class=\"s1\">When the product comes out of the mold it is completely intact (to obtain the vacuum effect it cannot have openings); it is then sent to the post-processing process or processes. <\/span><\/p>\n<p class=\"p1\"><span class=\"s1\">The finishing work is actually as important as the forming itself.<\/span><\/p>\n<p class=\"p1\"><span class=\"s1\">Fixing holes, or cut-through milling (e.g. to create cooling air intakes for medical or agricultural machines), or simply aesthetic finishing, may be obtained using drills and drilling cutters.\u00a0<\/span><\/p>\n<p class=\"p1\"><span class=\"s1\">The pieces may be also lacquered or painted over, to achieve the aesthetic value of a metallic body part.<\/span><\/p>\n<h3 class=\"p2\"><span class=\"s1 font-400 text-orange\">When should we choose thermoforming as a production technology?<\/span><\/h3>\n<p class=\"p1\"><span class=\"s1\">For more technical applications, the choice becomes almost natural when:<\/span><\/p>\n<ul class=\"ul1\">\n<li class=\"li1\"><span class=\"s1\">we are facing large dimension parts (e.g. a bathtub or a roof ski container for cars); <\/span><\/li>\n<li class=\"li1\"><span class=\"s1\">the production per year is around 5000 &#8211; 6000 pieces (for larger productions, compatibly with the size and <span class=\"Apple-converted-space\">\u00a0 <\/span><br \/>\ncomplexity of the piece, it is certainly useful to make a comparison with injection); <\/span><\/li>\n<li class=\"li1\"><span class=\"s1\">the weight\/surface ratio of the piece remains within the limits allowed by technology;<\/span><\/li>\n<li class=\"li1\"><span class=\"s1\">snap-fasteners are not required to be integrated into the piece; <\/span><\/li>\n<li class=\"li1\"><span class=\"s1\">the models of the object can change while remaining within the same general dimensions; <\/span><\/li>\n<li class=\"li1\"><span class=\"s1\">although for very small pieces there is not a real convenience, a case on its own is represented by disposable plates, glasses and trays. The large size of the sheets (up to 4mt2) allows to produce dozens of pieces at a time with a certain speed. The molds in this case make the difference because they give the shape and, at the same time, cut each single plate, thus reducing the recovery time of the pieces that can be automatically stacked by robots connected to the machine.<\/span><\/li>\n<\/ul>\n<h3 class=\"p2\"><span class=\"s1 font-400 text-orange\">The equipment<\/span><\/h3>\n<p class=\"p2\"><span class=\"s1\">The thermoforming molds can be made from various materials, also quite inexpensive, such as wood, for example. <\/span><\/p>\n<p class=\"p1\"><span class=\"s1\">Or fiberglass or, for very technical pieces and with high class finishes, in Aluminum.<\/span><\/p>\n<p class=\"p1\"><span class=\"s1\">Within certain limits it is possible to obtain pieces with undercuts, taking advantage of the elasticity of the material for extraction from the mold. In other more severe cases, or in presence of more fragile materials, the mold can be prepared with ad hoc movements to free the parts engaged in the undercuts.<\/span><\/p>\n<p class=\"p2\"><span class=\"s1\"><b>The main advantages of the thermoforming technology are:<\/b><\/span><\/p>\n<ul class=\"fa-ul\">\n<li class=\"p2\"><span class=\"s1\"><span class=\"fa-li\"><i class=\"fas fa-check-circle text-success\" style=\"\"><\/i><\/span>Possibility to produce large components with surfaces up to 4 m<\/span><span class=\"s4\"><sup>2<\/sup><\/span><span class=\"s1\"><br \/>\n<\/span><\/li>\n<li class=\"p2\"><span class=\"s1\"><span class=\"fa-li\"><i class=\"fas fa-check-circle text-success\" style=\"\"><\/i><\/span>Producing even heavy objects (up to 125kg)<br \/>\n<\/span><\/li>\n<li class=\"p2\"><span class=\"s1\"><span class=\"fa-li\"><i class=\"fas fa-check-circle text-success\" style=\"\"><\/i><\/span>Producing objects with thicknesses from 0.05 to 12mm<br \/>\n<\/span><\/li>\n<li class=\"p2\"><span class=\"s1\"><span class=\"fa-li\"><i class=\"fas fa-check-circle text-success\" style=\"\"><\/i><\/span>Reduced mold costs<br \/>\n<\/span><\/li>\n<li class=\"p2\"><span class=\"s1\"><span class=\"fa-li\"><i class=\"fas fa-check-circle text-success\" style=\"\"><\/i><\/span>Possibility to produce even small series<br \/>\n<\/span><\/li>\n<li class=\"p2\"><span class=\"s1\"><span class=\"fa-li\"><i class=\"fas fa-check-circle text-success\" style=\"\"><\/i><\/span>Low costs even in the case of frequent color changes<br \/>\n<\/span><\/li>\n<li class=\"p2\"><span class=\"s1\"><span class=\"fa-li\"><i class=\"fas fa-check-circle text-success\" style=\"\"><\/i><\/span>Multi material applications<br \/>\n<\/span><\/li>\n<li class=\"p2\"><span class=\"s1\"><span class=\"fa-li\"><i class=\"fas fa-check-circle text-success\" style=\"\"><\/i><\/span>Possibility to pre-decorate the visible surface of the sheet<br \/>\n<\/span><\/li>\n<li class=\"p2\"><span class=\"s1\"><span class=\"fa-li\"><i class=\"fas fa-check-circle text-success\" style=\"\"><\/i><\/span>Possibility of inserting metal inserts in the par<\/span><span class=\"s5\">t*<\/span><\/li>\n<\/ul>\n<p class=\"p2\"><span class=\"s5\">* <\/span><span class=\"s1\"><i>The inserts are positioned in the mold and wrapped in the hot material, which incorporates and anchors them.<br \/>\n<\/i><br \/>\n<b>Some disadvantages of this technique<\/b><\/span><\/p>\n<ul class=\"fa-ul\">\n<li><span class=\"fa-li\"><i class=\"fas fa-times-circle text-warning\" style=\"\"><\/i><\/span>The need to always finish the component by removing excess material<\/li>\n<li><span class=\"fa-li\"><i class=\"fas fa-times-circle text-warning\" style=\"\"><\/i><\/span>Management of the scrap<\/li>\n<li><span class=\"fa-li\"><i class=\"fas fa-times-circle text-warning\" style=\"\"><\/i><\/span>Difficulty in obtaining uniform thicknesses<\/li>\n<li><span class=\"fa-li\"><i class=\"fas fa-times-circle text-warning\" style=\"\"><\/i><\/span>Difficult to guarantee homogeneous temperature control<\/li>\n<li><span class=\"fa-li\"><i class=\"fas fa-times-circle text-warning\" style=\"\"><\/i><\/span>Strong dependence on the quality of semi-finished products (sheets or films) often purchased from external <span class=\"s1\">suppliers.<\/span><\/li>\n<\/ul>\n<p>Also in this case the raw materials play an important role for the final quality. The choice of the supplier becomes therefore strategic.<\/p>\n<div id='gallery-1' class='gallery galleryid-1586 gallery-columns-2 gallery-size-medium'><figure class='gallery-item'>\n\t\t\t<div class='gallery-icon landscape'>\n\t\t\t\t<a href='https:\/\/www.2milasrl.it\/wp-content\/uploads\/2020\/07\/FREEZER1_b.png'><img loading=\"lazy\" decoding=\"async\" width=\"400\" height=\"217\" src=\"https:\/\/www.2milasrl.it\/wp-content\/uploads\/2020\/07\/FREEZER1_b-400x217.png\" class=\"attachment-medium size-medium\" alt=\"\" srcset=\"https:\/\/www.2milasrl.it\/wp-content\/uploads\/2020\/07\/FREEZER1_b-400x217.png 400w, https:\/\/www.2milasrl.it\/wp-content\/uploads\/2020\/07\/FREEZER1_b-1536x832.png 1536w, https:\/\/www.2milasrl.it\/wp-content\/uploads\/2020\/07\/FREEZER1_b.png 1939w\" sizes=\"auto, (max-width: 400px) 100vw, 400px\" \/><\/a>\n\t\t\t<\/div><\/figure><figure class='gallery-item'>\n\t\t\t<div class='gallery-icon landscape'>\n\t\t\t\t<a href='https:\/\/www.2milasrl.it\/wp-content\/uploads\/2020\/07\/FREEZER2_b.png'><img loading=\"lazy\" decoding=\"async\" width=\"400\" height=\"217\" src=\"https:\/\/www.2milasrl.it\/wp-content\/uploads\/2020\/07\/FREEZER2_b-400x217.png\" class=\"attachment-medium size-medium\" alt=\"\" srcset=\"https:\/\/www.2milasrl.it\/wp-content\/uploads\/2020\/07\/FREEZER2_b-400x217.png 400w, https:\/\/www.2milasrl.it\/wp-content\/uploads\/2020\/07\/FREEZER2_b-1536x832.png 1536w, https:\/\/www.2milasrl.it\/wp-content\/uploads\/2020\/07\/FREEZER2_b.png 1939w\" sizes=\"auto, (max-width: 400px) 100vw, 400px\" \/><\/a>\n\t\t\t<\/div><\/figure><figure class='gallery-item'>\n\t\t\t<div class='gallery-icon landscape'>\n\t\t\t\t<a href='https:\/\/www.2milasrl.it\/wp-content\/uploads\/2020\/07\/FREEZER3_b.png'><img loading=\"lazy\" decoding=\"async\" width=\"400\" height=\"217\" src=\"https:\/\/www.2milasrl.it\/wp-content\/uploads\/2020\/07\/FREEZER3_b-400x217.png\" class=\"attachment-medium size-medium\" alt=\"\" srcset=\"https:\/\/www.2milasrl.it\/wp-content\/uploads\/2020\/07\/FREEZER3_b-400x217.png 400w, https:\/\/www.2milasrl.it\/wp-content\/uploads\/2020\/07\/FREEZER3_b-1536x832.png 1536w, https:\/\/www.2milasrl.it\/wp-content\/uploads\/2020\/07\/FREEZER3_b.png 1939w\" sizes=\"auto, (max-width: 400px) 100vw, 400px\" \/><\/a>\n\t\t\t<\/div><\/figure><figure class='gallery-item'>\n\t\t\t<div class='gallery-icon landscape'>\n\t\t\t\t<a href='https:\/\/www.2milasrl.it\/wp-content\/uploads\/2020\/07\/FREEZER4_b.png'><img loading=\"lazy\" decoding=\"async\" width=\"400\" height=\"217\" src=\"https:\/\/www.2milasrl.it\/wp-content\/uploads\/2020\/07\/FREEZER4_b-400x217.png\" class=\"attachment-medium size-medium\" alt=\"\" srcset=\"https:\/\/www.2milasrl.it\/wp-content\/uploads\/2020\/07\/FREEZER4_b-400x217.png 400w, https:\/\/www.2milasrl.it\/wp-content\/uploads\/2020\/07\/FREEZER4_b-1536x832.png 1536w, https:\/\/www.2milasrl.it\/wp-content\/uploads\/2020\/07\/FREEZER4_b.png 1939w\" sizes=\"auto, (max-width: 400px) 100vw, 400px\" \/><\/a>\n\t\t\t<\/div><\/figure>\n\t\t<\/div>\n\n<p>Computerized simulation allows to see how materials distribute in the mold during the thermoforming process.<\/p>\n","protected":false},"excerpt":{"rendered":"<p>In this information document, the last in the Conversion Technologies series, we shall talk about a technique \u2026 <a class=\"font-700 text-orange\" href=\"https:\/\/www.2milasrl.it\/en\/conversion-technologies-plastics-thermoforming\/\"> Read more<\/a><\/p>\n","protected":false},"author":2,"featured_media":1964,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"inline_featured_image":false,"footnotes":""},"categories":[9],"tags":[],"class_list":["post-1586","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-blog-en"],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v26.5 - 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