Aaron Lapinski. To prove to Industry that using a temperature controlled mold helps improve cycle consistency and part dimensions.

Aaron Lapinski

To prove to Industry that using a temperature controlled mold helps improve cycle consistency and part dimensions

To determine how a temperature controlled aluminum mold and non-temperature controlled Ren Shape mold of the same dimensions will affect shrinkage of a thermoformed ABS part.

To gain experience on the set up and operation of the industrial scale MAAC thermoformer

To develop a thermoforming lab experiment on the MAAC thermoformer for student education in Pennsylvania College of Technology’s BPS program.

To demonstrate to the thermoforming industry that a temperature controlled mold is essential for maintaining consistency in the finished product.

MAAC ThermoformerREN MoldAluminum temperature controlled

moldCirculator

Sterlco VISION 4410-C 250°F max temp

Hardness Density Density Tensile Compressive Compressive Modulus Flexural Flexural Glass Coefficient

Colorg/cc lbs/ft.3 Strength Strength Elasticity (psi) Strength Modulus Trans. Thermal

      psi psi   psi psi Temp (°F) Expansion                  (in/in/°F)

Ren Shape 472 81 0.88 55 7,000 10,900 460,000 9,540 416,000 248 25.8 x 10-6 Lt. Gray

Spartech ABS Amorphous Terpolymer .125 x 40 (W) x 22.5 (L) inches Premium Grade Natural Polished Finish

Sheet temperature 285-400of 340oF

Circulator settings 175-215oF 200oF

De-molding temperature 180-190oF

Dry ABS 180°F 24 hours

Hang the Mold Placement Center

Form partsCollect DimensionsPerform Mechanical Testing

Turn on Main Power Turn on Air Turn on Vacuum Turn on Fume Hood Enter MAAC software

PC62 Log in

Load or Build Program

Choose set up Turn on Vacuum

Pumps and Oven Index Clamps into

Oven on Diagnostics screen

Remove preheated clamps from oven

Open clampsPlace sheetStart cycle

Ren Shape Mold Production Trial

Aluminum Mold Production Trial

DOE

TimersOvensEncoders I.R. EyeMAACFlex

380°F55 Second Forming Time

HumidityRoom TemperatureMold Temperatures

Front Back TopClamp Temperature

Sheet Temperature De-molding Molding

B             8(Y1) 7(Y2) 6(Y3)

9 (X2) 5 (X2)

10 (X1) 4 (X1)

F             1(Y1) 2(Y2) 3(Y3)

Jig Dimensions

 Y Direction (MD) 15.875

X Direction (TD) 33.500

Mold Dimensions

 Y Direction (MD) 15.25

X Direction (TD) 31.125

Mold Dimensions

 Y Direction (MD) 15.25

X Direction (TD) 31.125

Mold Dimensions

 Y Direction (MD) 15.25

X Direction (TD) 31.125

Run Cooling Time Circulator Temp I.R. Eye Temp

1 - - -2 - - +3 - + -4 - + +5 + - -6 + + -7 + - +8 + + +

  High Low

Cooling Time 100 40

Circulator Temp 205 170

I.R. Eye Temp 400 340

HolesStuck to mold

cost/hr ($)

# of hours

Number of sheets

cost per sheet

Material Cost n/a n/a 75 $40.00 $3,000.00

Mentor 50 20 n/a n/a $1,000.00

Consultant 50 10 n/a n/a $500.00

Labor 18 100 n/a n/a $1,800.00 Thermoformer

cost100 85 n/a n/a $8,500.00

Testing Equipment

100 15 n/a n/a $1,500.00

REN Mold Cost n/a n/a n/a n/a $3,800.00 Aluminum Mold

Cost n/a n/a n/a n/a $7,500.00

Total cost$27,600.0

0

More Predictable dimensionsHigher mechanical propertiesShorter cycle times

Forming time from 100 to 55 seconds

 Ren

ShapeAluminum

Heating Time (seconds) 120 120Forming Time (seconds) 100 55Ejection Time (seconds) 2 2

Remove and load next part 30 30Total (seconds) 252 207

Time saving (seconds)/Part 45Time saving (seconds) /24 hour

day1080

Extra Parts/day 4.3Extra Parts/ 5 day week 21.4

Extra Parts/20 day month 85.7Extra Parts/50 week year 1071.4

Cost ($) / Sheet $40.00Extra Production / Year ($) $42,857.14

REN Mold Cost $3,800.00 Aluminum Mold Cost $7,500.00

Total Profit $39,157.14

Lack of KnowledgeMeasurement DeviceDryingGridsMold PositionCirculator Machine access

To determine how a temperature controlled aluminum mold and non-temperature controlled Ren Shape mold of the same dimensions will affect shrinkage of a thermoformed ABS part.

To gain experience on the set up and operation of the industrial scale MAAC thermoformer

To develop a thermoforming lab experiment on the MAAC thermoformer for student education in Pennsylvania College of Technology’s BPS program.

To demonstrate to the thermoforming industry that a temperature controlled mold is essential for maintaining consistency in the finished product.

Mr. Roger Kipp Mr. John Bartolomucci Mr. Gary McQuay Mr. Howard Troup Mr. Todd Kennedy Mr. Todd Crismer Mr. Brett Braker Mr. Chris Denmon McClarin Plastics Inc. Spartech Plastics Tooling Technology KYDEX LLC.

  "Acrylonitrile, Butadiene and Styrene (ABS) - FormTight Plastic

Thermoforming." Custom Packaging - Clamshells, Food Packaging, Blister Packaging - FormTight Plastic Thermoforming. Web. 27 Oct. 2010. <http://www.formtightinc.com/materials/ABS/default.html>.

  "Acrylonitrile Butadiene Styrene." Wikipedia, the Free

Encyclopedia. Web. 27 Oct. 2010. <http://en.wikipedia.org/wiki/Acrylonitrile_butadiene_styrene>.

  "Acrylonitrile-butadiene-styrene Copolymer (ABS) (chemical

Compound) -- Britannica Online Encyclopedia." Encyclopedia - Britannica Online Encyclopedia. Web. 27 Oct. 2010. <http://www.britannica.com/EBchecked/topic/4259/acrylonitrile-butadiene-styrene-copolymer>.

  "ASTM D638 - 10 Standard Test Method for Tensile Properties of

Plastics." ASTM International - Standards Worldwide. Web. 24 Apr. 2011. <http://www.astm.org/Standards/D638.htm>.