Brochure

The Society of Plastics Engineers is proud to announce its partnership with William K. McConnell in offering Ten Fundamentals of Thermoforming, a 2-Video Series accompanied by a 200-page Companion Volume. The videos provide a visually rich, dynamic view of the subject, while the Companion Volume provides details, including many useful tables, lists, and charts that could not be shown in the video. Both heavy-gauge and light-gauge thermoforming are covered. This program is the only thermoforming training product in the marketplace.

Footage for the videos was filmed at four plant locations: Prent Corporation, Milsco, Portage Casting & Mold and Thermoform Plastics. The videos are enhanced with 3-D animation and simulations that provide a look "behind the scenes" at the principles behind the manufacturing process. SPE is grateful to these companies for their cooperation and spirit of generosity.

Who will benefit from this series:
The two 45-minute videos and the Companion Volume were written for thermoforming's decision makers: supervisors, technicians, managers, process engineers, mold and product designers, cost estimators, maintenance staff, and quality personnel. The Safety, Effective Problem Solving, and Troubleshooting would be particularly valuable in the training of operators.

Materials and Machinery Suppliers who sell, or want to sell, into the thermoforming market, will also find value in the series as an information tool for customers.

Product Designers who must compare and choose among competing processes: thermoforming, injection molding, hand lay-up, and sheet molding compound will learn something of value.

Customers who buy and use thermoformed products will gain a greater understanding of what it takes to design, quote, and make the products. Both the thermoformer and customer will enjoy the benefits of clear, more effective communication.

Table of Contents:
Basic Thermoforming Methods: This chapter explores the most well-known processes and their advantages or disadvantages as they relate to tooling, forming, ancillary equipment and machinery. Schematics, line diagrams and photos are used to illustrate parts, processes and molds.

Costing: Costing can make the difference between profit and loss, yet it is easy to overlook vital details. Comprehensive checklists are included in this chapter to assist in establishing material, tooling and processing costs.

Mold and Product Design: Guidelines and checklists are presented, to help ensure that the appropriate steps are taken during the design cycle.

Involving the Appropriate Team: Producing a successful product involves cooperation from internal and external sources.

Plastic Materials: A synopsis of the two major classes of polymeric materials, and how they relate to the thermoforming process. Tables are provided for Key Material Properties and Standard ASTM Terminology for Abbreviated Terms.

Production of Film and Sheet by Extrusion: An overview of the extrusion process is the essential first step in the manufacture of thermoformed products. Understanding how film and sheet are made is an indispensable tool for establishing a repeatable process and building a good relationship with your supplier.

Heating Requirements: Sheet temperature and forming rate are crucial elements in thermoforming a quality part. This chapter explores how plastics are heated and how forming temperature affects both the material and the finished part.

Tooling:  Well designed and well built tooling is important to achieving consistent, economical thermoformed parts. Diagrams, checklists and tables are provided to help the thermoformer to make sound, informed decisions about tooling.

Vacuum and Compressed Air: Rapid, controlled forming is the key to consistent thermoformed parts, and vacuum and compressed air systems must be properly designed, built, and maintained. This chapter outlines the principles.

Good Thermoforming Practices: This final chapter discusses general rules of safety, the effects of ambient conditions on employees, materials, and the process; good record-keeping, achieving a repeatable process, monitoring the process, and logical problem solving. An extensive Troubleshooting table covers everything from blisters to tearing.