Purpose & Overview:
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, in expanding their knowledge and insight into today's fast pace and competitive design world.

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.

About the Instructor: Robert L. Browning
Robert Browning, of Atlanta Georgia, has 19 years experience in the design and engineering of single sheet, twin-sheet, and pressure thermoformed products, and tooling and processes. During this time he has had the opportunity to develop and refine new processes in thermoforming, and in the design of thermoforming tooling. As of July of 1999, he has six U.S. Patents, and two additional patents pending, for new and unique twin-sheet thermoforming and pressure forming products, tooling and processes.
Currently, an associate consultant with McConnell Co., Inc., Robert spent 15 years with Formex Manufacturing, Inc., one of the largest twin-sheet thermoforming companies in the U.S., as Director of Research, Development and Engineering. He has also had his own consulting firm, Isosceles, Inc., established in 1984, specializing in the design and engineering of consumer products. His experience includes all aspects of thermoforming: electronic housing design; prototype models; tooling design; vendor coordination; material research and specification; troubleshooting; development and implementation of Quality Control standards for products, materials, and process selection and specification. He also has an extensive working knowledge concerning patents, infringements, and product liability.

He attended Mercer University, with a major in Business Management, and the Georgia Institute of Technology, with a major in Industrial Design. Currently, working toward a Masters degree, he has had extensive courses in Materials & Processes; Management; Communication & Leadership; Employee Motivation; and New Technology.

His ability to define problems, develop alternatives, implement solutions, and his judgement in addition to his talents, have brought praise and respect from virtually all of his professional associates. At the present, he is an active member of the Industrial Design Society of America and is a Senior Member of the Society of Plastics Engineers.

Seminar Content:
Brief Background and History of Thermoforming • Process review • Single sided vacuum forming • Materials and properties • Thermoset vs. Thermoplastics • Molding and trimming
Tooling Design and Considerations • Undercuts • Male or female mold • Articulating molds • Plus assist • Tooling checklist review • Prototypes and samples
Creative Design Alternatives • Thermoforming • Pressure forming • Twin-sheet forming
Mechanical Considerations • How is part used • Effects of friction and wear • Ribs and gussets • Tolerances • Material thinning and control • Molded inserts and hardware
Environmental Considerations • Operating environment • Exposure to sunlight and weather Appearances, Finishes and Decorating • Style • Shape • Color • Texturing • Surface Finish • Molded-in details, names, logos
Design Limitations in Thermoforming • Do's and don'ts in design • When to look at other processes
Product Development Management • From design concept to troubleshooting