SPE Industrial Thermoforming Symposium & Workshop

Industrial Thermoforming Symposium & Workshop
For Thin & Heavy Gage Thermoforming for the 21st Century

March 9-13, 2008
Embassy Suites Dallas Market Center Hotel , Dallas, Texas

TECHNICAL PROGRAM

Sunday, March 9, 2008
Registration & Welcome Reception 6:00 pm – 8:00 pm



Monday, March 10, 2008 Registration 7:00 am – 8:30 am Symposium 8:30 am – 5:00 pm Reception 6.00 pm – 8:00 pm

Introduction – 8:30 am – 8:40 am Robert Browning Associate Partner, McConnell Co. Inc.

8:40 am – 9:15 am Manufacture of Sheet/Film Speaker: Bill McConnell President, McConnell Co. Inc.
	Extrusion Extrusion Laminating Co-extrusion Biax Calendering

9:15 am – 11:40 am Material Sheet Behavior and Testing for Processing Excellence and Quality Control in Thermoforming Speaker: Don Hylton Associate Partner, McConnell Company, Inc.
	Polymers Polymer Chemistry Effect on Processing Polymer Morphology Why it’s Important in Processing Types of Thermoforming Materials Amorphous Materials Crystalline Materials TPO Elastomer Materials How resin is manufactured TPO rheology Other Elastomers TPE, TPU, etc. Rheology and Viscoelasticity What is Viscoelasticity? Role of Viscoelasticity Effect on Processing Polymer Processing Principle of Accountability Process Flow Diagram Material Behavior in Processing Bulk Properties Heat Histories Part Performance 10:00 am – 10:15 am Coffee Break Material Testing ASTM Methods and Standards Tests for Formability Applicability Material Testing as a Quality Control Tool Specifications Laboratory QA/QC Material Specifications That Should be Considered When Ordering Material Specs for Cut-Sheet (heavy gage) Specs for Thin Gage (roll-fed)

11:45 am – 12:00 Noon Special: Texstars’ "Bird Strike Video"

12:00 noon – 1:00 pm Lunch

1:00 pm – 2:00 pm Process Controls Workshop Improved Production Capacity of Your Equipment by Use of Modernized Controls Speaker: Michelle Curenton, Sales Engineer, Facts, Inc.
	Modernize Controls Develop product codes for process variables How to tune controls to automatically adjust set points for closed-loop control algorithms (including platen movement, gage/profile, temperatures & when vacuum &/or compressed air is applied) How to improve quality & consistency with improved controls Use of trend charts/graphs & also alarming Data collection to assist in on-line troubleshooting/diagnostics

2:00 pm – 5:00 pm Thermoforming Methods Speaker: Arthur Buckel Associate-Partner McConnell Co. Inc.
	Webbing Vacuum Forming Why Fast Vacuum Needed Vacuum Pressure Measurements Surge Tanks, Vacuum Line and Solenoid Sizes, 90° and Elbows, etc. Pressure Forming (Use of Compressed Air) Free Pressure Forming Pressure Plate or Box Forming Pressure Box Forming – Roll Fed Thin Gage Mechanical Forming Stretch Forming Ridge Forming Strip Heating 3:00 pm – 3:15 pm Coffee Break Modifications of Basic Forming Methods Pre-stretching Snap Back—Male Mold Billow Snap Back—Male Mold Billow Snap Back (with a pressure chamber) Billow Snap—Female Mold (No Plug) Plug Assist—Female Mold Plug Assist Billow Plug Assist—Female Mold Twin Sheet Thermoforming Process Molds Twin Sheet Thermoforming Slip Forming Loose Clamping Frame Clamping Two Sides of Sheet Use of Multiple Vacuum Zones Forming of Composite Thermoplastic Sheet Material Properties Applications Mold Designs Sheet Heating & Forming Techniques Trimming 5:00 pm – Adjourn

Welcome Reception 6:00 pm – 8:00 pm


Tuesday, March 11, 2008 Symposium 8:30 am - 5:30 pm

8:30 am – 9:25 am Demonstration New Machine for Testing Thermoformability of Sheet/Film Dr. Amit Dharia President, Transmit Technology Group, LLC

9:45 am – 5:30 pm Plant Tours Depart hotel for plant tour at:
Spartech Plastics, Skyline Career Development Center, Kinro Composites Better Bath Division
6:30 pm – 9:00 pm Dinner - Trail Dust Steakhouse “Dress in your best cowduds!” - Funded By Our Sponsors Transportation is provided for the plant tours and dinner


Wednesday, March 12, 2008 8:30 am – 5:15 pm Heavy gage & thin gage sessions are held concurrently in different rooms.

THIN CAGE SESSION 8:30 am – 5:15 pm Characteristics of and Challenges in Thin-Gage Thermoforming Jim Throne, Consultant Sherwood Technologies Inc.

	Domestic Forming in a Global World
	Advantages and Risks in Following Your Customer Overseas
	Thin-Gage Materials
	Conventional Polymers - Anything New? APET and CPET OPS Foams Biopolymers (PLA and others) Nanopolymers?
	Machine Technologies
	Conventional machines Machines for the Clean Room Contact Forming Form, Fill and Seal Extrusion-Thermoforming Lines Wheel Machines Tilting Platen Machines Used v. Rebuilt v. New
	12:00 Noon – 1:00 pm - Lunch
	Trimming - Whys and Wherefores
	In-Press, In-Machine, In-Line - Which? Flat-Bed v. Canopy Tandem Trimming Trim Line Registration Issues Part Design Wall Thickness Control/Prediction Rim Rolling Detents and Other Closures
	Process Monitoring and Control Machine Safter in a Litigious Society
	Maintenance - Scheduled and Crisis Training and Retraining "Lock It, Pocket It"
5:15 pm – Adjourn

HEAVY CAGE (CUT-SHEET) SESSION 8:30 am – 5:15 pm Thermoforming Optically Clear & Class A Finished Parts

8:30 am – 10:00 am Guest Speaker: Jim Irion VP, Engineering, Texstars, Inc.
Material types & processes Forming optically clear canopies, windshields, etc. Secondary Treatments Inspection methods

10:00 am – 10:15 am - Coffee Break

10:15 am – 12:00 Noon Trimming Heavy Gage Guest Speaker: Robert Browning
Saftey in Trimming Trimming Tools Route and Drill Saw Die Cut, Sheer, Punch Steel Rule Dies Matched Punch Dies In-mold Dies Heated Dies Robotics Routing High Pressure Waterjet Laser Deburring

12:00 Noon – 1:00 pm Lunch

1:00 pm – 1:30 pm Rigidizing Thermoformed Parts Speaker: Bill McConnell
Bonded Doublers Fiber Glass Spray-up Twin Sheet Foam-in-Place Spray-up Foam

1:30 pm – 3:00 pm Tooling for Heavy Gage Guest Speaker: Robert Browning
Male versus Female Construction Vacuum Holes, Races, Slots Vacuum Zones & Moats Break-Aways & Undercuts Temperature Control Mechanical Helpers Spec Check List for Mold Design

3:00 pm – 3:15 pm Coffee Break

3:15 pm – 5:15 pm Turnkey Design & Mold Manufacturing Guest Speaker: Ken Griep Vice President, Portage Casting & Mold, Inc.
An initial Request for Quote Quotation Design and Prototype Part Mold Tryout Production

5:15 pm Adjourn




Thursday, March 13, 2008 Joint Thin and Heavy Gage Symposium 8:30 am – 5:30 pm

8:30 am – 10:00 am Heating the Sheet Speaker: Bill McConnell
Introduction Processing Temperatures & Enviornment Types of Heating Convection Preheat Oven for Roll Fed Machines Cell Cast Acrylic Ovens Heating of Heavy Gage Solid & Foam Sheet Prototype Forming Drying of Hydroscopic Sheet Such as ABS, PC, Etc. Conduction Conducting Heating Plates Form-Fill-Seal Thermoforming Heat-Form-Trin in Same Station (GN, Kirkoff, Etc. machines) Electromagnetic Radiation Coiled Resistance Wire Metal Tubular Heaters Flat Panel Heaters Ceramic Flat Aluminum Flat Steel Flat Quartz Glass (Such As Pyrex, etc.) Woven Quartz Cloth Quartz Tubes Gas Heaters Catalytic Heater Panels Open Flame Gas Heaters Halogen
10:00 am – 10:20 am Coffee Break

10:20 am – 12:00 Noon Infared Radiation Heat Imaging Systems Hands-On Demonstrations Joint Demonstration Leaders: Paul Ross, VP Solar Products, Inc. James Earle, Product Manager, Process Imaging Systems, Raytek Corp. Gail Segura, Central Regional Sales Manager, Raytek Corp.

This session will discuss the applied theory and recommended practice for making temperature measurements using infrared thermometers. Attendees will divide into three groups for "hands-on" demonstrations with selected instruments. Participants may bring their own infrared hand thermometers for use during this session. A free calibration check, <1000°F, on a certified blackbody calibration source will be made available for participants’ infrared thermometers. Avoiding the common pitfalls associated with high temperature reflections from heaters, transmitted radiation through thin sheet, and the challenge of measuring shiny metal molds will be among the topics demonstrated.

12:00 Noon – 1:00 pm - Lunch

1:00 pm – 5:15 pm Thermoforming Design for Designers of Thin and Heavy Gage Products Guest Speaker: Robert Browning

This is a comprehensive one-day seminar on thermoforming product design, and the development of plastic products using thermoforming, pressure forming and twin-sheet thermoforming. This intensive, fast paced seminar will help to provide a better understanding of thermoforming design, its limitations and advantages. Both designers and non-designers will appreciate this straightforward, hands-on course. The program is presented by an Industrial Designer, with lecture, slides, videos, sketches, samples, real world case studies and questions and answers. Attendees are encouraged to bring questions and their design problems for discussion. Additional topics include forming polycarbonates on composite molds; TPO materials and forming techniques; distortion printing & thermoforming; forming parts for the automotive and airline industry; all topics explained with case Studies. Brief Background and History of Thermoforming Process Review - Pro's & Con's of the Different Forming Methods Materials and Properties Thermoset vs. Thermoplastics Molding & Trimming Tooling/Mold Design and Considerations Undercuts Male or Female Molds Articulating Molds Plug Assist Tooling Checklist Review Prototypes & Samples Methods Pro's & Cons Creative Design Alternatives Thermoforming Pressure Forming Twin-sheet Forming Mechanical Considerations How is the Part Used Ribs Gussets Tolerances Material Thinning & Control Molded-in Inserts & Hardware Environmental Considerations Environment Exposure to UV & Weather Appearances, Finishes and Decorating Style Shape Color Texturing Surface Finish Molded-in Details Design Limitations in Thermoforming Do's and Don'ts in Design When to Look at Other Processes Product Development Management From Design Concept to Production Case Studies Distortion Printing & Thermoforming Troubleshooting
Special Case Study Presentations
Registration Forming of Distortion Printed Sheet Thermoforming TPO Materials Development of a High End Spa/Sauna

ADJOURN – 5:15 pm