thermoforming for the rail industry€¦ · thermoforming process types vacuum forming vacuum...
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f o r m i ng t h e f u tu re o f t r a n s p o r t a t i on
THERMOFORMING FOR
THE RAIL INDUSTRY
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THERMOPLASTICS FIBERGLASS
■ Lower part weight
■ Lower part cost through process efficiency
■ Better part definition and tolerances
■ Environmentally friendly
■ Enhanced interior design and enriched customer experience
■ Low cosmetic maintenance resistant to chipping, cracking, and discoloration
■ VOC Free
■ Tedlar Integrity
■ Meets SMP 800C and BSS 7239 ■
Structural contribution ■
THERMOPLASTICS VS. FIBERGLASS
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THERMOFORMING PROCESS
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WHAT IS
THERMOFORMING?
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HEAVY GAUGE FORMING
Heavy gauge parts are formed from material that is over .060” (1.5 mm) thick sheet stock.
Common Parts:
• Interior/exterior components for the automotive, mass transit, and aviation industries
• Equipment housing for commercial, medical, and industrial markets
• Instrument panels
• Office equipment
• Heavy-duty trays and in-process components
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MATERIAL TYPES
Virtually all thermoplastic materials can be
thermoformed. The most common materials used
in heavy gauge applications are:
• ABS
• HIPS
• HDPE
• PC*
• PVC
• PMMA
• TPO
* Flame, smoke, toxicity (FST) compliant materials are
used for rail applications
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Rapid
Polyurethane
Aluminum
THERMOFORMING MOLDS
Prototype Molds (non-metallic, not temperature controlled)
• Wood
• Plastic
• Polyurethane Modeling and Styling Board
• Fiberglass
• Ceramic
Production Molds (temperature controlled)
• Aluminum
- Cast
- Billet
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THERMOFORMING MACHINES
Rotary Formers
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THERMOFORMING PROCESS TYPES
Vacuum Forming
Vacuum forming is the most common process of thermoforming, whereby a sheet of plastic is heated to a forming temperature, stretched onto a single-surface mold, and forced against the mold by a vacuum to form into a shape.
Pressure Forming
Plastic pressure forming is a more advanced process used to form plastic sheet into a finely detailed molded shape. It utilizes a single-surface mold to create the formed shape while using vacuum & pressure on opposing sides of the sheet.
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THERMOFORMING PROCESSES
Vacuum Formed Pressure Formed
Image courtesy of Sekisui
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VACUUM FORMING PROCESS
• Material is stretched over mold
• Forming under atmospheric pressure
• Capable of providing high gloss parts, approaching class A surface quality
• Tightest outside radii are at least 1.5x thickness of the material
• Distorted texture
• Inconsistent gloss
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VACUUM FORMING TOOLING
Positive or Negative Molds
• Aluminum
- Cast
- Billet
• Bead blast or sand blast texture to evacuate air
• Coupled with:
- Sealing Ring
- Draw Box
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PRESSURE FORMING PROCESS
• Material stretched and pressed into mold
• Forming under pressurized air – 241 kPa (35 PSI) to 414 kPa (60 PSI)
• Uniform texture
• Consistent gloss
• Undercuts possible
• Small protrusion present from vacuum hole
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PRESSURE FORMING TOOLING
Positive or Negative Molds
• Aluminum
- Cast
- Billet
• Structure to withstand pressure
• Tool is textured
- Acid Etch
- Bead blast
• Tool is engraved
• Coupled with:
- Pressure Box – Shallow Draw
- Pressure Box with Plug Assist – Deep Draw
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PRODUCTION: TRIMMING
Methods
• Hand Trimming
• Band Saw
• Shaper
• Router
• Punch and Die Sets
• Cutting Die
• Steel Rule
• Forged
KMT trimming video
• Laser
• Water Jet
• Routing (Machining)
• CNC (5 axis)
• Robotic (7 axis)
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MATERIAL SELECTION
• Thermoplastic material to replace fiberglass (FRP)
• Low smoke
- 49CFR238.103 & NFPA 130
• Low toxicity
- SMP800C & BSS 7239
• Base material
- Polycarbonate blend
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• No film• No protection on base material
• Lowest cost
• Films • Applied at time of extrusion ensure long lasting
durability and performance
• PVDF
- Clear (base material provides color)
- Varying gloss levels
- Graffiti resistant
- Chemical resistant
- UV resistant
- Mid-level cost
• PVF*
- Printed Color and Pattern
- Graffiti resistant
- Chemical resistant
- UV resistant
- Highest cost
MATERIAL SELECTION
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PROCESS SELECTION
• Pressure Forming or Vacuum Forming?
• Review of Requirements
- Texture
- Gloss
- Detail: Logo/Engraving
- Tool Cost
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TOOLING SELECTION
• Production or Prototype
• Negative or Positive
• Pressure Forming or Vacuum Forming
• Part Volume
• Number of Cavities
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Rapid
Polyurethane
Aluminum
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QUESTIONS?
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THANK YOU
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