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formech_1372:formech_1372 [2020/06/04 01:55] – formlab | formech_1372:formech_1372 [2023/12/18 00:46] – [Control panel] formlab | ||
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- | [Vacuum Forming Guide](https:// | + | === Pre-drying === |
+ | * PMMA: 70°C 4 hours | ||
+ | |||
+ | |||
+ | [[https:// | ||
---- | ---- | ||
+ | ===== Mould tips ===== | ||
+ | |||
+ | <WRAP center round important 60%> | ||
+ | Moulds should not contain moisture or dust (!) since it could harm the vacuum pump. | ||
+ | </ | ||
+ | |||
+ | |||
+ | * Can the mould be removed after forming? | ||
+ | * {{: | ||
+ | * {{: | ||
+ | * {{: | ||
+ | * Include draft angles:\\ {{: | ||
+ | * Can the vacuum reach all pockets? | ||
+ | * {{: | ||
+ | * Can it withstand the pressure? | ||
+ | * Can it withstand the heat? | ||
+ | ==== Tested mould materials include: ==== | ||
+ | * **Plaster** | ||
+ | * <color orange> | ||
+ | * **Wood** | ||
+ | * <color orange> | ||
+ | * **PU foam** | ||
+ | * <color orange> | ||
+ | * <color green> | ||
+ | * <color green> | ||
+ | * <color green> | ||
+ | * <color green> | ||
+ | * <color red> | ||
+ | * <color red> | ||
+ | * **3D printed parts** | ||
+ | * <color red> | ||
+ | * Plastic deforms: infill becomes visible if not enough top layers or walls. | ||
+ | * ... | ||
+ | |||
+ | ===== Available sheet materials ===== | ||
+ | |||
+ | {{: | ||
+ | ==== PETG - Polyethylene terephthalate glycol-modified ==== | ||
+ | Transparent, | ||
+ | |||
+ | ^ Thickness ^ Size ^ Cost (per sheet) ^ | ||
+ | | 1mm | Large - 1370 x 660mm | €16,10 | | ||
+ | | 2mm | Large - 1370 x 660mm | €32,20 | | ||
+ | | 1mm | Small - 500 x 500mm | €4,20 | | ||
+ | | 2mm | Small - 500 x 500mm | €7,14 | | ||
+ | | 3mm | Small - 500 x 500mm | €10,36 | | ||
+ | |||
+ | ---- | ||
+ | |||
+ | {{: | ||
+ | PMMA samples | ||
+ | ==== PMMA - Poly(methyl methacrylate) ==== | ||
+ | |||
+ | PMMA is also known as Acryl. It has a glossy surface. | ||
+ | |||
+ | ^ Color ^ Light ^ Thickness | ||
+ | | White | translucent | 3mm | large - 1370 x 660mm | €39,20 | | ||
+ | | White | translucent | 3mm | small - 500 x 500mm | €11,20 | | ||
+ | | Green | transparent | 3mm | small - 500 x 500mm | €16,80 | | ||
+ | | Light blue | translucent | 3mm | large - 1370 x 660mm | €58,80 | | ||
+ | | Light blue | translucent | 3mm | small - 500 x 500mm | €16,80 | | ||
+ | | Dark blue | transparent | 3mm | large - 1370 x 660mm | €58,80 | | ||
+ | | Dark blue | transparent | 3mm | small - 500 x 500mm | €16,80 | | ||
+ | | Yellow | transparent | 3mm | small - 500 x 500mm | €16,80 | | ||
+ | | Cream | transparent | 3mm | large - 1370 x 660mm | €58,80 | | ||
+ | | Cream | transparent | 3mm | small - 500 x 500mm | €16,80 | | ||
+ | |||
+ | ---- | ||
+ | |||
+ | {{: | ||
+ | polystyrene samples | ||
+ | |||
+ | ==== PS - Polystyrene ==== | ||
+ | Uncut sheets. These can be used for the large and small forming area. | ||
+ | |||
+ | ^ Color ^ Surface finish | ||
+ | | white | matte / glossy | 1mm | 2000X1200 | €19,63 | | ||
+ | | white | matte / glossy | 1,5mm | 2000X1200 | €28,88 | | ||
+ | | white | matte / matte | 4mm | 2000X1000 | €63,42| | ||
+ | | black | matte / matte | 1mm | 2000X1200 | €22,06 | | ||
+ | | black | matte / glossy | 1,5mm | 2000X1200 | €35,19 | | ||
+ | | red | matte / matte | 1mm | 2000X1200 | €22,06 | | ||
+ | | red | matte / glossy | 1,5mm | 2000X1200 | €35,19 | | ||
+ | | green | matte / matte | 1,5mm | 2000X1200 | €34,03 | | ||
=== How much does it cost? === | === How much does it cost? === | ||
- | < | + | |
- | startup cost + ( plastic sheet cost * plastic sheet count * material multiplier ) | + | startup cost + ( plastic sheet cost * plastic sheet count * material multiplier ) |
+ | + | ||
- | ( machine time (minutes) * machine time cost ) | + | |
- | </ | + | |
* startup cost: €2: only when vacuum form machine is used | * startup cost: €2: only when vacuum form machine is used | ||
* plastic sheet cost: cost sheet, including VAT and transportation | * plastic sheet cost: cost sheet, including VAT and transportation | ||
- | * material multiplier: 30%: item cost * 1,3 | + | * material multiplier: item cost * 1,4 |
- | * machine time cost: €5 per hour (€0, | + | * machine time cost: €8 per hour (€0, |
- | === Plastic sheet prices | + | ===== Materials allowed in Formlab ===== |
- | PETG CLEAR - FULL (1370 x 660) - 1mm: €13,00 per piece\\ | + | **HIPS** |
- | PETG CLEAR - WINDOW (500 x 500) - 1mm: €3,90 per piece\\ | + | * **Typical uses**: display, packaging & light weight internal applications |
- | PETG CLEAR - WINDOW | + | * **Strength**: Moderate |
- | PETG CLEAR - WINDOW (500 x 500) - 3mm: €9,62 per piece\\ | + | * **Brand names**: no specific brands listed. |
+ | * **Formability**: | ||
+ | * **Hygroscopic** | ||
+ | * **Forming temp range**: '' | ||
+ | * **Conclusion**: an entry level plastic, easy to form & not expensive | ||
- | VIKUGLAS PMMA XT OPAAL - FULL (1370 x 660) - 3mm: €36,4 per piece\\ | + | **PETG** |
- | VIKUGLAS PMMA XT OPAAL - WINDOW | + | * **Typical uses**: Clear covers & reverse printed signage |
+ | * **Strength**: | ||
+ | * **Brand names**: Vivak, Spectar | ||
+ | * **Formability**: | ||
+ | * **Hygroscopic** | ||
+ | * **Forming temp range**: '' | ||
+ | * **Conclusion**: | ||
- | ALTUGLAS PMMA GROEN - FULL (1370 x 660) - 3mm: €54,6 per piece\\ | ||
- | ALTUGLAS PMMA GROEN - WINDOW (500 x 500) - 3mm: €15,6 per piece\\ | ||
- | ALTUGLAS PMMA LICHTBLAUW | + | **HDPE** |
- | ALTUGLAS PMMA LICHTBLAUW - WINDOW | + | * **Typical uses**: Outdoor play equipment, pond liners |
+ | * **Strength**: | ||
+ | * **Brand names**: no specific brands listed. | ||
+ | * **Formability**: | ||
+ | * **Hygroscopic** | ||
+ | * **Forming temp range**: '' | ||
+ | * **Conclusion**: | ||
- | ALTUGLAS PMMA DONKERBLAUW | + | **PP** |
- | ALTUGLAS PMMA DONKERBLAUW - WINDOW | + | * **Typical uses**: Outdoor furniture and packaging applications |
+ | * **Strength**: | ||
+ | * **Brand names**: no specific brands listed. | ||
+ | * **Formability**: | ||
+ | * **Hygroscopic** | ||
+ | * **Forming temp range**: '' | ||
+ | * **Conclusion**: | ||
- | ALTUGLAS PMMA GEEL - FULL (1370 x 660) - 3mm: €54,6 per piece\\ | + | ---- |
- | ALTUGLAS PMMA GEEL - WINDOW (500 x 500) - 3mm: €15,6 per piece\\ | + | |
- | ALTUGLAS PMMA CRÈME | + | ===== Materials NOT allowed in Formlab ===== |
- | ALTUGLAS PMMA CRÈME - WINDOW (500 x 500) - 3mm: €15,6 per piece\\ | + | **ABS** |
+ | * hygroscopic | ||
- | PS WIT 900 glans/mat 1mm 2000X1200: €18,226 per piece\\ | + | **PC** - // |
- | PS WIT 900 glans/mat 1,5mm 2000X1200: €26,819 per piece\\ | + | * hygroscopic |
- | PS WIT 900 MAT/MAT 4mm 2000X1000: €45,30 per piece \\ | + | * cools down really fast |
- | PS ZWART 840 MAT/MAT 1mm 2000X1200: €20,49 per piece\\ | + | * **Forming temp range**: '' |
- | PS ZWART 840 glangs/mat 1,5mm 2000X1200: €32,67 per piece\\ | + | * //Formech//: Polycarbonate is a challenging material to form at the best of times but it can be formed on all of our machines providing the correct procedures are followed. 4mm PC should really be formed using a double heater machine. If you can use clear PETG life is a lot easier. It’s not quite as impact resistant as PC but it does not need to be pre-dried which is a real benefit.\\ If you don’t have the facilities to pre-dry the material, then you are at a disadvantage because the material is unlikely to reach the correct forming temperature. PC should be formed at between 175C – 225C. You will also need to pre-dry the material (with the protective film covering removed) in an oven for a few hours before forming to reach these temperatures, otherwise you will get blistering on the sheet because of the water content. |
- | PS ROOD 173 MAT/MAT 1mm 1200X1200: €20,49 per piece\\ | + | **PVC** - //polyvinyl chloride// |
- | PS ROOD 173 glans/mat 1,5mm 2000X1200: €32,67 per piece\\ | + | * when burnt, gives off hydrochloric acid |
- | PS GROEN 843 MAT/MAT 1,5mm 2000X1200: €31,59 per piece\\ | + | **PMMA** - // |
+ | * brand name: Acryl | ||
+ | * hygroscopic | ||
+ | * brittle | ||
- | PS BLAUW 5010 glans/mat 1,5mm 2000X1200: €32,67 per piece\\ | + | **PET** - // |
+ | * Narrow heating band | ||
+ | * will crystallise if over heated | ||
+ | ===== General tips ===== | ||
+ | * // | ||
+ | * // | ||
+ | * // | ||
+ | * **Bubble moulding**: The table should be lowered. If it's in the up-position, | ||
+ | |||
+ | |||
+ | ===== Drying sheets with the oven ===== | ||
+ | |||
+ | Use one of the ceramics oven in the metal atelier.\\ | ||
+ | The control cabinet is behind the oven. \\ | ||
+ | {{: | ||
+ | |||
+ | |||
+ | Get the key from Peter to be able to power on the oven.\\ | ||
+ | To turn on the oven, insert the key and turn it to the right. Then turn the red knob to the right.\\ | ||
+ | |||
+ | ==== Control panel ==== | ||
+ | |||
+ | {{: | ||
+ | |||
+ | * There are 9 programs | ||
+ | * Each program can have multiple segments | ||
+ | * Example: segment 1: warm up to 70° in 30 min, segment 2: keep that temperature for 4 hours | ||
+ | * Each segment has 2 values: a temperature, | ||
+ | |||
+ | |||
+ | - Press ' | ||
+ | - Nothing is on here yet. (This might change in the future) | ||
+ | - Press until there' | ||
+ | - In the future there might be a paper with an explanation of what programs do what. I could have a fixed entry on the list | ||
+ | - Segment 1' is blinking. Use the up-down arrows to set a target temperature | ||
+ | - Press the --> arrow to go to the time value | ||
+ | - Set the time with the up-down arrows | ||
+ | - When ready, press the stop / start button to start the oven. | ||
+ | |||
+ | ==== Suggested program ==== | ||
+ | |||
+ | * Segment 1: temp: 70° time: 30 min | ||
+ | * Segment 2: temp: 70° time: 4 hours | ||
+ | * Segment 3: temp: 0° time: 30 min | ||
+ | ===== Clamping tips for high gauge sheets ===== | ||
+ | * Apply 80 grit strips of sand paper to the underside of the clamp frame to provide more grip on the sheet. The strips can be held in place with a good quality double sided tape, contact adhesive or preferably a silicone adhesive to take the heat. | ||
+ | * Apply strips of 50mm wide self-adhesive aluminium foil tape all around the edges of the sheet and tape the sheet down to the aperture plate or bottom plate of the reducing window to try and stop the sheet from pulling out.\\ {{: | ||
+ | * If you are using a reducing window, then check with a feeler gauge where there is insufficient clamping and add to the top of the reducing window bottom plate angle iron to stiffen it up. | ||
+ | * Cut the sheet larger than required, drill holes in the perimeter of the sheet outside of the clamping frame. Then use these holes to secure the sheet with bolts, wires etc. to stop the sheet from pulling out at the tool rises.\\ {{: | ||
+ | * Check you have even pressure on the clamping on each side.\\ {{: | ||
+ | |||
+ | |||
+ | ===== Machine presets ===== | ||
+ | |||
+ | ==== PS ==== | ||
+ | * 1mm (Experimental v2) | ||
+ | * Power: 70% | ||
+ | * Heating: 45 seconds | ||
+ | * 2.5mm (Experimental v2) | ||
+ | * Power: 70% | ||
+ | * Heating: 85 seconds | ||
+ | |||
+ | ==== PETG ==== | ||
+ | * 2mm (OK) | ||
+ | * Power: 70% | ||
+ | * Heating: 70 seconds | ||
+ | |||
+ | ==== PMMA ==== | ||
+ | * 3mm | ||
+ | * pre-dry: 4 hours at 70°C (between 70-80°C): no blisters | ||
+ | * If using the window: add shims: 3 on each side. | ||
+ | * heater 70% (and 75% at the edges) | ||
+ | * 125 sec heating | ||
+ | * (without peeking in between) | ||
+ | * This results in ±168°C: nice and flexible. | ||
+ | * Sheet forming temperature: | ||
+ | * 60 sec cooling | ||
+ | |||
+ | |||
+ | ==== Medium Gauge Film ==== | ||
+ | * 0,15mm | ||
+ | * profile: 1mm PET (heater 85%) | ||
+ | * heating: 8 seconds | ||
+ | * vacuum: manual operation: start-stop technique to avoid holes if there are large cavities | ||
---- | ---- | ||
+ | ===== Troubleshooting ===== | ||
+ | ==== Preset loading gives wrong values ==== | ||
+ | |||
+ | Reason of problem: touch screen input is too fast for the slow computer (PLC) | ||
+ | |||
+ | Fix: | ||
+ | * **Use firm, deliberate presses with your finger** (not a stylus or fingernail). | ||
+ | * Don’t try to be too fast. | ||
+ | |||
+ | |||
+ | ==== Sheet pulls itself out of the clamping frame ==== | ||
+ | // | ||
+ | |||
+ | {{: | ||
+ | If you are using a reducing window, then you will have to make sure that you have good clamping on each side of the aperture. The reducing window seals are flat silicone sponge and do not have the same gripping effect as the round silicone bead seal. | ||
+ | |||
+ | {{: | ||
+ | // | ||
+ | |||
+ | ==== Blisters appear on the surface ==== | ||
+ | There is moisture in the sheet. At the point the blisters appear, the sheet is not hot enough to form yet. You'll need to dry the sheet or switch to a non hygroscopic material. | ||
- | === PMMA 3mm === | + | ==== Pre-stretch button does nothing ==== |
- | * heater 75% en 80% | + | * Turn off air supply |
- | * 230 sec heating (no longer) | + | * Turn off Formech |
- | * 60 sec cooling | + | * Wait ±1 minute and turn Formech back on. |
- | * --> Worked reasonably well | + | * If you can hear the relay click, it works and the air supply can be opened again. |
- | * --> This is lower heat for a longer period | + | |
+ | ==== Heater timer doesn' | ||
+ | * Enable the heater. (The timer doesn' | ||
- | === Medium Gauge Film (0,15mm) === | ||
- | * profile: 1mm PET (heater 85%) | ||
- | * heating: 8 seconds | ||
- | * vacuum: manual operation: start-stop technique to avoid holes if there are large cavities |