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formech_1372:formech_1372 [2020/06/23 02:05] – formlab | formech_1372:formech_1372 [2024/03/01 01:38] (current) – [Medium Gauge Film] formlab | ||
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* Large: '' | * Large: '' | ||
- | [Vacuum Forming Guide](https:// | + | === Pre-drying === |
- | ---- | + | * PMMA: 70°C 4 hours |
- | ===== Available sheet materials ===== | ||
+ | [[https:// | ||
+ | ---- | ||
- | {{: | + | ===== Mould tips ===== |
- | ==== PS - Polystyrene ==== | + | <WRAP center round important 60%> |
- | * Uncut sheets. These can be used for the large and small forming area. | + | Moulds should not contain moisture or dust (!) since it could harm the vacuum pump. |
- | * Thicknesses: | + | </ |
- | * Colors: White, red, black (black has a glossy side), green, blue | + | |
- | ^ Color ^ Surface finish | ||
- | | white | matte / glossy | 1mm | 2000X1200 | €18,20 | | ||
- | | white | matte / glossy | 1,5mm | 2000X1200 | €26,80 | | ||
- | | white | matte / matte | 4mm | 2000X1000 | €45,30| | ||
- | | black | matte / matte | 1mm | 2000X1200 | €20,50 | | ||
- | | black | matte / glossy | 1,5mm | 2000X1200 | €32,70 | | ||
- | | red | matte / matte | 1mm | 2000X1200 | €20,50 | | ||
- | | red | matte / glossy | 1,5mm | 2000X1200 | €32,70 | | ||
- | | green | matte / matte | 1,5mm | 2000X1200 | €31,60 | | ||
- | | blue | matte / glossy | 1,5mm | 2000X1200 | €32,70 | | ||
+ | * 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 ===== | ||
- | === How much does it cost? === | + | {{: |
+ | ==== PETG - Polyethylene terephthalate glycol-modified | ||
+ | Transparent, | ||
- | < | + | ^ Thickness ^ Size ^ Cost (per sheet) |
- | startup cost + ( plastic | + | | 1mm | Large - 1370 x 660mm | €16,10 | |
- | + | + | | 2mm | Large - 1370 x 660mm | €32,20 | |
- | ( machine time (minutes) * machine time cost ) | + | | 1mm | Small - 500 x 500mm | €4,20 | |
- | </ | + | | 2mm | Small - 500 x 500mm | €7,14 | |
+ | | 3mm | Small - 500 x 500mm | €10,36 | | ||
- | * startup cost: €2: only when vacuum form machine is used | + | ---- |
- | * plastic sheet cost: cost sheet, including VAT and transportation | + | |
- | * material multiplier: 30%: item cost * 1,3 | + | |
- | * machine time cost: €5 per hour (€0, | + | |
+ | {{: | ||
+ | PMMA samples | ||
+ | ==== PMMA - Poly(methyl methacrylate) ==== | ||
- | === Plastic sheet prices === | + | PMMA is also known as Acryl. It has a glossy surface. |
- | PETG CLEAR - FULL (1370 x 660) - 1mm: €13,00 per piece\\ | + | ^ Color ^ Light ^ Thickness |
- | PETG CLEAR - WINDOW (500 x 500) - 1mm: €3,90 per piece\\ | + | | White | translucent | 3mm | large - 1370 x 660mm | €39,20 | |
- | PETG CLEAR - WINDOW (500 x 500) - 2mm: €6,63 per piece\\ | + | | White | translucent | 3mm | small - 500 x 500mm | €11,20 | |
- | PETG CLEAR - WINDOW (500 x 500) - 3mm: €9,62 per piece\\ | + | | 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 | | ||
- | VIKUGLAS PMMA XT OPAAL - FULL (1370 x 660) - 3mm: €36,4 per piece\\ | + | ---- |
- | VIKUGLAS PMMA XT OPAAL - WINDOW (500 x 500) - 3mm: €10,4 per piece\\ | + | |
- | ALTUGLAS PMMA GROEN - FULL (1370 x 660) - 3mm: €54,6 per piece\\ | + | {{: |
- | ALTUGLAS PMMA GROEN - WINDOW (500 x 500) - 3mm: €15,6 per piece\\ | + | polystyrene samples |
- | ALTUGLAS PMMA LICHTBLAUW | + | ==== PS - Polystyrene ==== |
- | ALTUGLAS PMMA LICHTBLAUW - WINDOW (500 x 500) - 3mm: €15,6 per piece\\ | + | Uncut sheets. These can be used for the large and small forming area. |
- | ALTUGLAS PMMA DONKERBLAUW - FULL (1370 x 660) - 3mm: €54,6 per piece\\ | + | ^ Color ^ Surface finish |
- | ALTUGLAS PMMA DONKERBLAUW - WINDOW (500 x 500) - 3mm: €15,6 per piece\\ | + | | 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 | | ||
- | ALTUGLAS PMMA GEEL - FULL (1370 x 660) - 3mm: €54,6 per piece\\ | + | === How much does it cost? === |
- | ALTUGLAS PMMA GEEL - WINDOW (500 x 500) - 3mm: €15,6 per piece\\ | + | |
- | ALTUGLAS PMMA CRÈME - FULL (1370 x 660) - 3mm: €54,6 per piece\\ | ||
- | ALTUGLAS PMMA CRÈME - WINDOW (500 x 500) - 3mm: €15,6 per piece\\ | ||
- | PS WIT 900 glans/mat 1mm 2000X1200: €18,226 per piece\\ | + | startup cost + ( plastic sheet cost * plastic sheet count * material multiplier ) |
- | PS WIT 900 glans/mat 1,5mm 2000X1200: €26,819 per piece\\ | + | + |
- | PS WIT 900 MAT/MAT 4mm 2000X1000: €45,30 per piece \\ | + | ( machine time (minutes) * machine time cost ) |
- | PS ZWART 840 MAT/MAT 1mm 2000X1200: €20,49 per piece\\ | + | |
- | PS ZWART 840 glangs/mat 1,5mm 2000X1200: €32,67 per piece\\ | + | |
- | PS ROOD 173 MAT/MAT 1mm 1200X1200: €20,49 per piece\\ | ||
- | PS ROOD 173 glans/mat 1,5mm 2000X1200: €32,67 per piece\\ | ||
- | PS GROEN 843 MAT/MAT 1,5mm 2000X1200: €31,59 per piece\\ | + | * startup cost: €2: only when vacuum form machine is used |
- | + | * plastic sheet cost: cost sheet, including VAT and transportation | |
- | PS BLAUW 5010 glans/ | + | * material multiplier: item cost * 1,4 |
+ | * machine time cost: €8 per hour (€0,08333333 | ||
- | |||
- | ---- | ||
- | |||
- | |||
- | === PMMA 3mm === | ||
- | * heater 75% en 80% | ||
- | * 230 sec heating (no longer) | ||
- | * 60 sec cooling | ||
- | * --> Worked reasonably well | ||
- | * --> This is lower heat for a longer period | ||
- | |||
- | |||
- | === 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 | ||
- | |||
- | ---- | ||
===== Materials allowed in Formlab ===== | ===== Materials allowed in Formlab ===== | ||
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* **Forming temp range**: '' | * **Forming temp range**: '' | ||
* **Conclusion**: | * **Conclusion**: | ||
- | |||
- | |||
- | |||
---- | ---- | ||
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* // | * // | ||
* // | * // | ||
+ | * **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 ===== | ===== 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 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. | ||
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* Check you have even pressure on the clamping on each side.\\ {{: | * 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 | ||
+ | |||
+ | * Polypropylene sheet: 1mm | ||
+ | * No profile saved | ||
+ | * Heaters at 50% | ||
+ | * Heating: ±70 sec. Ready when sheet starts pulling flat. Might be ready much earlier too, but these values are the ones we used for testing. The plastic is very stretchy and blew holes in tiny cavities. So maybe better less heat. | ||
+ | ---- | ||
===== Troubleshooting ===== | ===== Troubleshooting ===== | ||
- | === Sheet pulls itself out of the clamping frame === | + | ==== 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 ==== | ||
// | // | ||
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// | // | ||
- | === Blisters appear on the surface === | + | ==== 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. | 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. | ||
+ | ==== Pre-stretch button does nothing ==== | ||
+ | * Turn off air supply | ||
+ | * Turn off Formech | ||
+ | * Wait ±1 minute and turn Formech back on. | ||
+ | * If you can hear the relay click, it works and the air supply can be opened again. | ||
+ | |||
+ | ==== Heater timer doesn' | ||
+ | * Enable the heater. (The timer doesn' | ||