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
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PS Polystyrene• Applications
F d & di l k i– Food & medical packaging– Toys– Electronic housings– DisplaysDisplays– Refridgerator interiors
CLEM N.V. Spinnerijkaai 39, B-8500 Kortrijk
ABS Acryl Butadiene Styrene• Properties
I i– Impact resistant– Well deformable– Easy to glue– Modified = limited outside useModified limited outside use– Fairly chemical resistant
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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
CLEM N.V. Spinnerijkaai 39, B-8500 Kortrijk
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
CLEM N.V. Spinnerijkaai 39, B-8500 Kortrijk
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)
CLEM N.V. Spinnerijkaai 39, B-8500 Kortrijk
PP Polypropylene• Properties
R i hi h– Resistant to high temperatures– Ductile– Not sensitive to aging– CheapCheap– No well thermoformable
CLEM N.V. Spinnerijkaai 39, B-8500 Kortrijk
PP Polypropylene• Applications
F d– Food– Automotive– Technical products– PackagingPackaging
CLEM N.V. Spinnerijkaai 39, B-8500 Kortrijk
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
CLEM N.V. Spinnerijkaai 39, B-8500 Kortrijk
PE Polyethylene• Applications
R f il– Roof tiles– Automotive– Transport trays– Machine partsMachine parts– Safety hoods
CLEM N.V. Spinnerijkaai 39, B-8500 Kortrijk
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
CLEM N.V. Spinnerijkaai 39, B-8500 Kortrijk
PMMA Polymethylmethacrylate• Applications
Li h d i i– Light advertising– Transparant hoods for machines– Baths & showers– Roof domesRoof domes– Design lighting
CLEM N.V. Spinnerijkaai 39, B-8500 Kortrijk
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
CLEM N.V. Spinnerijkaai 39, B-8500 Kortrijk
PC Polycarbonate• Applications
M hi– Machinery– Transparant parts for exteriors (anti vandalism)– Lighting (fire resistant)– Safety windowsSafety windows– Safety helmets
CLEM N.V. Spinnerijkaai 39, B-8500 Kortrijk
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
CLEM N.V. Spinnerijkaai 39, B-8500 Kortrijk
PET Poly Ethene Tereftalate• Applications
P k i– Packaging– Food– Bottles for softdrinks– DisplaysDisplays– Cable insulation
CLEM N.V. Spinnerijkaai 39, B-8500 Kortrijk
Hybrids• Blends: ABS,PC/ABS,PS/PP,KYDEX,
TPOTPO• Co extrusion: ABS/PMMA• Combined sheets: PE + 3mm foam
CLEM N.V. Spinnerijkaai 39, B-8500 Kortrijk
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
CLEM N.V. Spinnerijkaai 39, B-8500 Kortrijk
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
CLEM N.V. Spinnerijkaai 39, B-8500 Kortrijk
CCCLEMCLEM
VACUUM FORMINGVACUUM FORMINGVACUUM FORMING VACUUM FORMING
dHr. Verheust V.
CLEM N.V. Spinnerijkaai 39, B-8500 Kortrijk
Overview• Vacuum forming ?
• Commonly used techniques
• Design: opportunities restrictions
• Finishing g
• Projectsj
CLEM N.V. Spinnerijkaai 39, B-8500 Kortrijk
Vacuum forming ?Thermoplastic, semimanufactured product in plate form p
3-D product
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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)
CLEM N.V. Spinnerijkaai 39, B-8500 Kortrijk
Forming
Heated plateMould
Clamp systemp y
Temp. control channels
Vacuum channel
channels
CLEM N.V. Spinnerijkaai 39, B-8500 Kortrijk
Forming machines 2 basic concepts 2 basic concepts
• Single-station (discontinuous)
• Multi-station(quasi-continuous)(q )
CLEM N.V. Spinnerijkaai 39, B-8500 Kortrijk
Forming machines
Single-station Multi-station (carrousel)
3 different treatment stations(loading/unloading, heating, forming)
1 treatment station
CLEM N.V. Spinnerijkaai 39, B-8500 Kortrijk
(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
CLEM N.V. Spinnerijkaai 39, B-8500 Kortrijk
Usual positive forming
Heating
Elastic
iForming
CLEM N.V. Spinnerijkaai 39, B-8500 Kortrijk
Usual positive forming
V i bl ll hi k improvement via• Variable wall thickness improvement viapre-blowing or
vacuum• Inside – correct dimensions
vacuum
CLEM N.V. Spinnerijkaai 39, B-8500 Kortrijk
Application
CLEM N.V. Spinnerijkaai 39, B-8500 Kortrijk
Positive forming + pre-blowing
• Better division of wall thickness via pre-blowing
1. Pre-blowing
2. Vacuum
CLEM N.V. Spinnerijkaai 39, B-8500 Kortrijk
Positive forming + pre-blowing
CLEM N.V. Spinnerijkaai 39, B-8500 Kortrijk
Applications
CLEM N.V. Spinnerijkaai 39, B-8500 Kortrijk
Application
CLEM N.V. Spinnerijkaai 39, B-8500 Kortrijk
Positive forming + vacuum
• Better division of wall thickness via vacuum
Vacuum
CLEM N.V. Spinnerijkaai 39, B-8500 Kortrijk
Application
Lighting hood (base: 500 x 350)
(h i ht 600)(height: 600)
CLEM N.V. Spinnerijkaai 39, B-8500 Kortrijk
Negative forming
Variable wall thickness
Vacuum
CLEM N.V. Spinnerijkaai 39, B-8500 Kortrijk
Negative forming
Improvement via• Variable wall thickness Improvement via stamp
• Outside – correct dimensions
CLEM N.V. Spinnerijkaai 39, B-8500 Kortrijk
Application
CLEM N.V. Spinnerijkaai 39, B-8500 Kortrijk
Negative with stamp • Better division of wall thickness via stamp
1. Stamp1. Stamp stretching
2 V2. Vacuum
CLEM N.V. Spinnerijkaai 39, B-8500 Kortrijk
Applications
CLEM N.V. Spinnerijkaai 39, B-8500 Kortrijk
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
CLEM N.V. Spinnerijkaai 39, B-8500 Kortrijk
Applications
CLEM N.V. Spinnerijkaai 39, B-8500 Kortrijk
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
CLEM N.V. Spinnerijkaai 39, B-8500 Kortrijk
Negative HPF
• Variable wall thickness • Adding texture to the surface is possible
CLEM N.V. Spinnerijkaai 39, B-8500 Kortrijk
Negative HPF with stamp
• Better division of wall thickness via stamp• Adding texture to the surface is possible
CLEM N.V. Spinnerijkaai 39, B-8500 Kortrijk
Twin sheet forming
• 2 sheets are heated up simultaneously + formed + welded
CLEM N.V. Spinnerijkaai 39, B-8500 Kortrijk
Design:Design:opportunities restrictionsopportunities restrictions
• Variable wall thickness
Positive Negative
• 1 side with correct dimensions as a result of contact with mould
CLEM N.V. Spinnerijkaai 39, B-8500 Kortrijk
Design:Design:opportunities restrictions
• Ideal angle
opportunities restrictions g
135 °, ideal 90°, good 60°, to be avoided
to be avoided better best
CLEM N.V. Spinnerijkaai 39, B-8500 Kortrijk
Design:Design:opportunities restrictions
• Conics
opportunities restrictions
A id d t th h th ibl• Avoid undercuts, though they are possible
CLEM N.V. Spinnerijkaai 39, B-8500 Kortrijk
Design:Design:opportunities restrictions
• 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
CLEM N.V. Spinnerijkaai 39, B-8500 Kortrijk
with controlled temperature
Design:Design:opportunities restrictions
• Draw ratio
opportunities restrictions
initial thickness average final thickness
Draw ratio = sum of all surfaces initial surface
=
CLEM N.V. Spinnerijkaai 39, B-8500 Kortrijk
FinishingFrom plate to final product
Vacuum forming with automatic loader
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automatic loader
FinishingFrom plate to final product
5-axis milling 3D measurement bench
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bench
Projects
• Realised projects in very diverse domains – Medical sector
Automotive sector / transport– Automotive sector / transport– Industry– Design & display– Art – ...
CLEM N.V. Spinnerijkaai 39, B-8500 Kortrijk
Projects
• Medical sector
Part of radiology device Communication aid
CLEM N.V. Spinnerijkaai 39, B-8500 Kortrijk
Projects
• Automotive sector / transport
Bodywork Roof part
CLEM N.V. Spinnerijkaai 39, B-8500 Kortrijk
Projects
• Industry
Housing of a loom Internal door
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Projects
• Design & display
CLEM N.V. Spinnerijkaai 39, B-8500 Kortrijk
Projects
• Art
Pieces of scenery
CLEM N.V. Spinnerijkaai 39, B-8500 Kortrijk
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