IQS Newsroom Articles on Vacuum Forming
About Vacuum Forming and Vacuum Forming Services Including
Blister
Packs, Clamshells, Pressure
Forming, Thermoforming & Vacuum
Formed Plastics.
Vacuum forming is a plastic
thermoforming process
that involves forming thermoplastic sheets into three-dimensional shapes through
the application of heat and pressure. In general terms, vacuum forming services
are all sheet forming methods, including drape forming, which is one of the
most popular services. Basically during the vacuum forming process, plastic
material is heated until it becomes pliable, and then it is placed over a mold
and drawn in by a vacuum until it takes on the desired shape. Vacuum thermoforming
is a great method for producing plastic parts that have sharp details and fit
nicely to specific products.
During the vacuum forming process, a sheet of heated plastic material
is placed over a male or female mold. The mold then moves towards the sheet
and presses against it to create a seal. Next, the application of a vacuum
draws out the air between the mold and the sheet so that the plastic conforms
to the mold exactly. This is accomplished through venting holes in the mold
that are joined to vacuum lines. The mold also has a water cooling system integrated
into it that brings the temperature of the plastic to the set temperature needed.
When the curing temperature is reached and the piece is formed, air blows back
into the mold and separates the new part from the mold.
Vacuum forming services produce plastic parts for various industries,
such as the food, cosmetic, medical, electronics, entertainment, household
products, toys, athletic equipment, appliance, automotive, office supplies
and clothing industries. One of the most important industries that thermoforming serves, however, is packaging. Products like blister
packs, inserts, trays
and clamshells are used to house other products and are important for both
preservation of the items they hold and the aesthetic designs they can provide.
Consumer product manufacturers often use vacuum forming to produce plastic
trays and glasses. Another interesting use for vacuum formed plastic is the
creation of signs for gas stations and convenience stores.
The greatest advantage to vacuum forming services is that it involves
less parts and tooling than injection molding, and therefore is more cost-effective.
It is an economical choice that can be used for small and medium production
runs, with low cost tool modifications. There is great design flexibility available,
from a variety of prototypes to custom made designs that can be used to cover
almost any product. Most manufacturers also offer a wide variety of trim and
other decoration options that can prove quite a visual advantage. Time of production
is generally short, which frees up time to do more detail-oriented aspects
of production. Sharp, precise detail is available for many products, which
makes vacuum
formed plastics an attractive alternative to other molding processes.
Types of Vacuum Forming and Vacuum Forming Manufacturers
- are clear plastic, nonresealable packaging used for products that could be tampered with.
- are plastic packages that have hinges to open and close like a clam's shell.
- is like snapback forming except
that the thermoplastic sheet is stretched to the base of the mold.
In both cases, the use of air to stretch the material prior to vacuum
sealing and application to the mold permits the material to thin uniformly.
- is a thermoforming procedure that uses a plug or male
mold to press the heated thermoplastic material into the female mold
prior to the application of a vacuum. This method helps uniformly
distribute the sheet.
-
is a thermoforming procedure that involves applying pressure to the
top of the plastic sheeting while the vacuum force pulls downward. Pressure
forming is done through air pressure or mechanical means, and provides
greater precision because the plastic is able to attain a greater definition
of shape in the mold.
- is the process of pre-stretching the sheet
material with a vacuum box. A partial vacuum is then applied
to the box, just enough for the necessary stretching, and the mold
is
pushed
into the material where the box is vented to atmospheric pressure
that draws on a vacuum.
- is vacuum thermoforming using only female
molds that produce a material distribution that is the opposite
of the results
obtained from male molds.
- involves heating and stretching plastics.
- are created by a thermoforming process that uses a vacuum to suck the plastic sheet into a mold.
Vacuum Forming Vacuum Forming Manufacturers Terms
- The dark particles that appear
in plastic film during thermoforming processes because of contamination.
- The characteristic of some plastics of losing their colors
when coming into contact with water or certain solvents. Also, this is
the undesirable movement of materials to the surface of plastic or into
an adjacent material.
- Thermoformed semi-rigid plastic shells, typically made
to conform to the shape of the product being packaged.
- A protrusion on a plastic part that adds strength, assists
with alignment in assembly and allows for fastenings.
- Portions of thermoformed plastic where vacuum and
heat produce an opening in weak or thin points.
- A change in the structure of a plastic material.
- The detachment of thermoformed parts, like blisters, from
one another for the next phase of the packaging procedure.
- The process of removing static electricity from
plastic so that less dust clings to it.
(http://www.iqsdirectory.com/die-cutting/)
- The use of a steel rule die to cut finished sheets of blisters
or blister cards to create individual pieces.
- The degree to which the sidewall of a blister or
clamshell is tapered to smooth the progress of the removal from the thermoforming
mold and denesting of the blister.
- A technique that creates depressions in a specific
pattern on plastic film and sheeting.
- The tendency of thermoformed plastic
to crack under the influences of certain chemicals.
- A blister
card that is scored and die cut, permitting entrapment of the blister
between the two halves of the card. This supplies a seal between two boards
or between a board and a blister flange, especially useful when blister
packaging heavy items.
- The process of joining two or more plastics together
with the application of heat and pressure.
- The result of inadequate contact of the plastic material
with the surface of the mold due to trapped air, moisture on the surface
of the mold or low pressure in irregular indentations on the material's
surface.
- A model of an intended
part. Prototypes show the final size as well as the design.
- Thermoplastic material derived from industrial
plastic scrap from a different processor.
- The flow of heated plastic
sheeting in a thermoforming procedure in which molten plastic sheets sag
before forming. The distance of the sag is determined by an electric eye
and is good for determining the forming readiness of the material.
- A heating procedure before forming a thermoplastic
sheet that involves heating both sides.
- Any plastic material,
which is not part of the product, that results from a molding procedure.
This material is typically tip scrap and can be reused.
- The construction required to create plastic sheeting,
comprised of an extruder, die, polish rolls, conveyor, draw rolls, cutter
and a stacker.
- The minute change in length or volume of a
material when subjected to heat.
- A double blister for encapsulating a product
for product visibility on two sides.
- An indentation or protrusion that hinders the removal
from a mold.