Monday, March 5, 2007
Registration 7:00 am – 8:30 am
Symposium 8:30 am – 5:00 pm

This three-part materials study is designed to provide:

1. A basic understanding of material behavior in thermoforming.
2. The variables that affect performance in every phase of the process from polymerization to end-use.
3. Sheet testing and specifications.

The sessions include discussions on material attributes such as,morphology (shape and structure), rheology (flow properties), and blending, with emphasis on their effect on thermoforming behavior. There is information on why certain materials form better than others; thermoplastic elastomers and their behavior; crystalline materials and how they differ from amorphous materials; and why some materials have unique properties such as moisture retention. In addition, the attendee learns the importance of testing for forming consistency and excellence and how testing helps us understand and specify forming behavior.
The course provides a summary of ASTM and other relevant laboratory tests for thermoformability. It also explains how and why specific material properties should be tested and how to incorporate this understanding into quality management.

1. Polymers
1. Polymer Chemistry
   1. Effect on Processing
2. Polymer Morphology
   1. Why it’s Important in Processing
2. Types of Thermoforming Materials
   1. Amorphous Materials
   2. Crystalline Materials
   3. TPO Elastomer Materials
      1. How resin is manufactured
      2. TPO rheology
   4. Other Elastomers TPE, TPU, etc.

   10:00 am – 10:15 am Coffee break

3. Rheology and Viscoelasticity
   1. What is Viscoelasticity?
   2. Role of Viscoelasticity
   3. Effect on Processing
4. Polymer Processing
   1. Principle of Accountability
   2. Process Flow Diagram
   3. Material Behavior in Processing
   4. Bulk Properties
   5. Heat Histories
      1. Exrusion
      2. Heating, Cooling
      3. Post Extrusion Converting
   6. Part Performance
5. Material Testing
   1. ASTM Methods and Standards
   2. Tests for Formability
   3. Applicability
6. Material Testing as a Quality Control Tool
   1. Specifications
   2. Laboratory QA/QC
7. Material Specifications That Should be Considered When Ordering Material
   1. Specs for Cut-Sheet (heavy gage)
   2. Specs for Thin Gage (roll-fed)

1. Webbing
2. Vacuum Forming
   1. Why Fast Vacuum Needed
   2. Vacuum Pressure Measurements
   3. Surge Tanks, Vacuum Line and Solenoid Sizes, 90° and Elbows, etc.
3. Pressure Forming (Use of Compressed Air)
   1. Free Pressure Forming
   2. Pressure Plate or Box Forming
   3. Pressure Box Forming – Roll Fed Thin Gage
4. Mechanical Forming
   1. Stretch Forming
   2. Ridge Forming
   3. Strip Heating

1. Pre-stretching
2. Snap Back—Male Mold
   1. Billow Snap Back—Male Mold
   2. Billow Snap Back (with a pressure chamber)
3. Billow Snap—Female Mold (No Plug)
4. Plug Assist—Female Mold
   1. Billow Plug Assist—Female Mold
5. Twin Sheet Thermoforming
   1. Process
   2. Molds
   3. Twin Sheet Thermoforming Machines
6. Slip Forming
   1. Loose Clamping Frame
   2. Clamping Two Sides of Sheet
   3. Use of Multiple Vacuum Zones

• Spartech Plastics: Custom Sheet Extrusion Plant

• · Kinro Composites (Better Bath Components): A Large Custom Thermoforming Plant

1. Software That Allows Management, Scheduling Customers' Orders and Monitoring All, Utilizing PLC to Track in Progress
   1. Simplify order scheduling process
   2. Monitor productivity in Real Time Environment
   3. Second job status info
   4. Easily manage open orders portfolio
   5. Collect production data for analysis
   6. Ability to monitor any machine in your facilities
      ... on your laptop computer from anywhere!

1. Hurdles to Overcome When Thermoforming at 55-60 Cycles/Minute
   1. Press movement
   2. Press design
   3. High speed film sheet/film indexing system
   4. Control systems
   5. Process air sequencing

1. Introduction
   Thermoforming Sheet/Film Processing Temperatures Environment
2. Types of Heating
   1. Convection
      1. Preheat Oven for Roll Fed Machines
      2. Cell Cast Acrylic Ovens
      3. Heating of Heavy Gauge Solid and Foam Sheet
      4. Prototype Forming
      5. Drying of Hydroscopic Sheet Such As ABS, PC, Etc.
   2. Conduction
      1. Conduction Heating Plates
      2. Form-Fill-Seal Thermoforming Machines
      3. Heat-Form-Trim in Same Station Machines (GN, Kirkoff, Etc.)
   3. Radiation
      1. Electromagnetic Radiation Introduction
      2. Types of Radiant Heat
         1. Coiled Resistance Wire
         2. Metal Tubular Heaters
         3. Flat Panel Heaters
            1. Ceramic
            2. Flat Aluminum
            3. Flat Steel
            4. Flat Quartz
            5. Glass (Such as Pyrex, etc.)
            6. Woven Quartz Cloth
         4. Quartz Tubes
         5. Gas Heaters
            1. Catalytic Heater Panels
            2. Open Flame Heaters
         6. Halogen

Thursday, March 8, 2007 8:30 am - 5:00 pm
The heavy gage and thin gage sessions are held concurrently on Thursday

12:00 noon - 1:00 pm Lunch

Session 2 - Thin Gage Thermoformers 8:30 am - 5:00 pm
12:00 noon - 1:00 pm Lunch
Roll-Fed Thermoforming ?Choosing the Right Machine & Tooling Options
Speakers:
Barry Shepherd, President, Shepherd Thermoforming & Packaging
Rita Webb, Sales Engineer, ODC Tooling & Molds.

1. Roll-fed machine alternatives
   1. In-line steel rule die
   2. Off line matched metal trim
   3. Cut-in-place
   4. Inexpensive models
   5. Extrusion in-line
2. Pushing the limits of roll-fed equipment
   1. Materials being run today
   2. Size limitations
   3. Optional equipment
   4. Cycle time limit
3. Tooling Options - How to select the right one!
   1. Form &Trim In-place vs. Form & Trim Inline
   2. Forged Kisscut trim vs. Matched Metal trim
   3. Male vs. Female molds
   4. Interchangeability
   5. Quick-Change
4. Specialty Tooling Applications
   1. CPET Food Trays
   2. 3rd Motion Plug Assist Forming
   3. Large Bed - Family Molds
   4. Berry Baskets - Sidewall vented containers
   5. Deep-draw Polyolefins
   6. Contour / Automotive applications
5. Trouble Shooting - Barry Shepherd & Rita Webb

Special Case Study Presentations

• Registration Forming of Distortion Printed Sheet
• Thermoforming TPO Materials
• Development of a High End Spa/Sauna