Clem plastic shaping

CCCLEMCLEM

OverviewOverview thermoplasticsthermoplastics

PS

OverviewOverview thermoplasticsthermoplastics

PE• PS• ABS

• PE• PMMA

• PVC • PC• PP • PET

C t i– Co extrusion– Blends

CLEM N.V. Spinnerijkaai 39, B-8500 Kortrijk

PS Polystyrene• Properties

V ll d f bl– Very well deformable– Dimensionally stable– High gloss– CheapCheap– Not very chemical resistant

N t i t t t UV– Not resistant to UV


PS Polystyrene• Applications

F d & di l k i– Food & medical packaging– Toys– Electronic housings– DisplaysDisplays– Refridgerator interiors


ABS Acryl Butadiene Styrene• Properties

I i– Impact resistant– Well deformable– Easy to glue– Modified = limited outside useModified limited outside use– Fairly chemical resistant


ABS Acryl Butadiene Styrene• Applications

A i i d– Automotive industry– Electronic houdings– Machinery– Available with special properties like fireAvailable with special properties like fire

retardant and antistatic


PVC Poly Vinyl Chloride• Properties

G d i li h d h idi– Good resistance to light and humidity– Strong and not brittle– Optical transparancy is possible– Long life spanLong life span– Fairly chemical resistant

Chl id li k l d th h b i– Chloride links are released through burning


PVC Poly Vinyl Chloride• Applications

R f d d i i– Roof gutters and drain pipes– Outside doors– Machinery– Electrical insulationElectrical insulation– Medical housings (fire safety)


PP Polypropylene• Properties

R i hi h– Resistant to high temperatures– Ductile– Not sensitive to aging– CheapCheap– No well thermoformable


PP Polypropylene• Applications

F d– Food– Automotive– Technical products– PackagingPackaging


PE Polyethylene• Properties

V i i– Very impact resistant– Very resistant to UV (black)– Very chemical resistant– Hard to glueHard to glue– Bad form stability

R i t t t h idit– Resistant to humidity


PE Polyethylene• Applications

R f il– Roof tiles– Automotive– Transport trays– Machine partsMachine parts– Safety hoods


PMMA Polymethylmethacrylate• Properties

Cl– Clear transparant– Very printable– Easy to deform– Not so impact resistantNot so impact resistant– UV stabile and colourfast

C t & t d d lit– Cast & extruded quality


PMMA Polymethylmethacrylate• Applications

Li h d i i– Light advertising– Transparant hoods for machines– Baths & showers– Roof domesRoof domes– Design lighting


PC Polycarbonate• Properties

V i i i h hi h/l ’– Very impact resistant with high/low temp’s– High temperature resistance: 140°C– Very transparant– Suited for exterior with a UV coatingSuited for exterior with a UV coating– Good fire resistance

H idit b b t– Humidity absorbant– Relative expensive


PC Polycarbonate• Applications

M hi– Machinery– Transparant parts for exteriors (anti vandalism)– Lighting (fire resistant)– Safety windowsSafety windows– Safety helmets


PET Poly Ethene Tereftalate• Properties

G d– Good transparancy– Low temperature resistance: 65°C– Very tough– Good thermoformableGood thermoformable– Good chemical resistance

F f t– Formfast– Good fire resistance


PET Poly Ethene Tereftalate• Applications

P k i– Packaging– Food– Bottles for softdrinks– DisplaysDisplays– Cable insulation


Hybrids• Blends: ABS,PC/ABS,PS/PP,KYDEX,

TPOTPO• Co extrusion: ABS/PMMA• Combined sheets: PE + 3mm foam


Bayloy ®• Bayloy 10: opaque coloured polycarbonate

sheetssheets• Bayloy 21: PC/PETG blend• Bayloy 40: opaque APET sheets

B l 50 l d PETG h t• Bayloy 50: opaque coloured PETG sheets• Bayblend: PC/ABS blendy


Kydex• Properties

I i S iff– Impact resistant– Fire resistant

– Stiffness– Resilient

– Chemical resistance– Very good

– Dimensional stability– Easy to colourVery good

thermoformableNo pre drying needed

Easy to colour– Low minimal order

quantity– No pre-drying needed– Abrasive resistance

quantity


CCCLEMCLEM

VACUUM FORMINGVACUUM FORMINGVACUUM FORMING VACUUM FORMING

dHr. Verheust V.


Overview• Vacuum forming ?

• Commonly used techniques

• Design: opportunities restrictions

• Finishing g

• Projectsj


Vacuum forming ?Thermoplastic, semimanufactured product in plate form p

3-D product


Vacuum forming - process

3 stages in the process

Heating up Forming Cooling

(plate thickness sort of material)(plate thickness, sort of material)(form place dependent)


Forming

Heated plateMould

Clamp systemp y

Temp. control channels

Vacuum channel

channels


Forming machines 2 basic concepts 2 basic concepts

• Single-station (discontinuous)

• Multi-station(quasi-continuous)(q )


Forming machines

Single-station Multi-station (carrousel)

3 different treatment stations(loading/unloading, heating, forming)

1 treatment station


(loading/unloading, heating, forming)

Commonly used techniques • Positive forming

– Usual positive forming – Forming using pre-blowing – Forming a vacuum

• Negative forming – Usual negative forming – Forming with stamp – Forming using pre-blowing, stamp and vacuum

Hi h f i (HPF)• High pressure forming (HPF)• Twin sheet forming g


Usual positive forming

Heating

Elastic

iForming


Usual positive forming

V i bl ll hi k improvement via• Variable wall thickness improvement viapre-blowing or

vacuum• Inside – correct dimensions

vacuum


Application


Positive forming + pre-blowing

• Better division of wall thickness via pre-blowing

1. Pre-blowing

2. Vacuum


Positive forming + pre-blowing


Applications


Application


Positive forming + vacuum

• Better division of wall thickness via vacuum

Vacuum


Application

Lighting hood (base: 500 x 350)

(h i ht 600)(height: 600)


Negative forming

Variable wall thickness

Vacuum


Negative forming

Improvement via• Variable wall thickness Improvement via stamp

• Outside – correct dimensions


Application


Negative with stamp • Better division of wall thickness via stamp

1. Stamp1. Stamp stretching

2 V2. Vacuum


Applications


Negative forming with pre-Negative forming with preblowing, stamp and vacuum

• Better division of wall thickness Better division of wall thickness

1. Pre-blowing

2 St2. Stamp stretching

3. Vacuum


Applications


High pressure forming (HPF)

At atmosphere High pressure

A t l ?Acute angles? •Almost always negative

•Acute angles no problem

•Adding texture to the surface is possible


Negative HPF

• Variable wall thickness • Adding texture to the surface is possible


Negative HPF with stamp

• Better division of wall thickness via stamp• Adding texture to the surface is possible


Twin sheet forming

• 2 sheets are heated up simultaneously + formed + welded


Design:Design:opportunities restrictionsopportunities restrictions

• Variable wall thickness

Positive Negative

• 1 side with correct dimensions as a result of contact with mould


Design:Design:opportunities restrictions

• Ideal angle

opportunities restrictions g

135 °, ideal 90°, good 60°, to be avoided

to be avoided better best



• Conics

opportunities restrictions

A id d t th h th ibl• Avoid undercuts, though they are possible



• Depth of draw

opportunities restrictions p

Stamp necessary ?necessary ?

S d d• Secondary draw Strong thinning of wall thickness

Stamp from above i h ll d


with controlled temperature


• Draw ratio

opportunities restrictions

initial thickness average final thickness

Draw ratio = sum of all surfaces initial surface

=


FinishingFrom plate to final product

Vacuum forming with automatic loader


automatic loader

FinishingFrom plate to final product

5-axis milling 3D measurement bench


bench

Projects

• Realised projects in very diverse domains – Medical sector

Automotive sector / transport– Automotive sector / transport– Industry– Design & display– Art – ...


Projects

• Medical sector

Part of radiology device Communication aid


Projects

• Automotive sector / transport

Bodywork Roof part


Projects

• Industry

Housing of a loom Internal door


Projects

• Design & display


Projects

• Art

Pieces of scenery


Clem plastic shaping

Business

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