thermoforming 2006 16th annual thermoforming conference...to the music city. i am ready and hope to...

S-1 Thermoforming16TH CONFERENCE SECTION

Thermoforming 200616th Annual Thermoforming Conference

September 17th – 20th, 2006

For More Information:

Conference Chairman: Dr. Martin Stephenson, Placon Corporation608.275.7215 Fax 608.278.4423

[email protected]

Technical Chairman: Mike Lowery, Premier Plastics414.423.5940 Fax 414.423.5930

[email protected]

Parts Competition Chairman: James Alongi, Maac Machinery630.665.1700 Fax 630.665.7799

[email protected]

Conference Coordinator: Gwen Mathis706.235.9298 Fax 706.295.4276

[email protected]

CHECK OUT OUR WEBSITES AT:http://www.4spe.org/communities/divisions/d25.php

www.thermoformingdivision.com

NASHVILLE CONVENTIONCENTER

RENAISSANCE HOTEL

NASHVILLE, TENNESSEE


Martin Stephenson

“CREATIVITY & INNOVATIONIN THERMOFORMING”

Nashville, Tennessee

September 17th – 20th, 2006

I would like to take this opportunity to invite you

the 16th Annual SPE Thermoforming Conference

to be held in “Music City” – Nashville, Tennessee.

Many of you have requested a Sunday evening start

as opposed to the usual Saturday night. In response to

this request, the 2006 Conference will kick off on

Sunday evening, September 17th and go through

Wednesday, September 20th, 2006 with a theme of

“Creativity and Innovation in Thermoforming.” This

will be our third time in the “Music City” and we are

glad to be back in Nashville! The 1998 and 2002

conferences were well attended and highly rated and

we know that the 2006 Conference will be no

exception!

Planning for the conference has already begun. Mike

Lowery (Premier Plastics), Technical Chair for 2006,

and I are very excited about the direction of our

program. We have already lined up speakers from

North America and Europe to conduct both seminars

and joint sessions. Many people in our industry are

very creative and innovative and we are working to

bring them to speak in Nashville. Topics we will cover

will be competing in today’s hotly competitive global

market, dealing with issues of cost vs. value, and the

technical aspects of innovations in the Thermoforming

Industry, i.e. material processing, tooling technology,

and machinery. This is an excellent forum to launch

your new products and conduct business with the

leaders of the thermoforming industry.

The convention center in Nashville is a very dynamic

location with friendly people to tailor to your needs.

We think 2006 will be our largest show ever, so reserve

your space now to exhibit. If your company has never

sponsored before, we invite you to look at the value

one gets by sponsoring. We do have a lottery to draw

the sponsors due to the response we get each year. It

is a great value! Even if you are not drawn as a sponsor,

you will move down to the top of the list to select

your exhibit space. Our SPE Thermoforming Board

is grateful for the continuous support our sponsors

and exhibitors give us each year. We could not do it

without you!

Nashville is a very economical venue so that

companies can bring CEOs, Sales/Marketing

Executives, along with their Engineering and

Operations people. This year’s Conference aims to

have a particular orientation toward the men and

women in the trenches (Engineering and Operations)

of the Thermoforming Industry.

It is never too soon to reserve your space for 2006.

Gwen Mathis, Conference Coordinator, is happy to

help you. Please call her at 706.235.9298, (fax)

706.295.4275 or e-mail: [email protected].

The bands are warming up and awaiting your arrival

to the Music City. I am ready and hope to see you in

Nashville for a successful Conference in 2006! ■


FIRST CALL FOR SPONSORS/EXHIBITORS

16th Annual Thermoforming Conference & Exhibition

September 17th - 20th, 2006

NASHVILLE CONVENTION CENTER

Nashville, Tennessee

Gwen Mathis, Conference Coordinator

“THERMOFORMING 2006:CREATIVITY & INNOVATION IN THERMOFORMING”

T he 16th Annual Thermoforming Conference and Exhibition – “Thermoforming 2006: Creativity& Innovation in Thermoforming” – plans are beginning to take shape. This show will be a forum

for the newest techniques, latest equipment, materials, auxiliary equipment and current industry news.As an Exhibitor, this event will enable you to showcase your products and services at the only showgeared just to THERMOFORMERS! If your company sells to THERMOFORMERS, then this isthe place you must be. This industry event is a prime opportunity for you to reach the decision makersin the field and create a brighter future for your business as well.

Full exhibits will be offered. Our machinery section continues to grow each year. If you are notparticipating in our machinery section, you are encouraged to do so. Each 10' x 10' booth is fullypiped, draped, carpeted and a sign will be provided. As an extra value, one comp full registration isincluded with every booth sold. This gives your attendees access to all Technical Sessions, Work-shops, Special Events, Plant Tours and all meals. A great bargain at $2,250.00.

Where else can you make personal contact with more than 1,000 individuals who are directly in-volved with our industry. Your SPONSORSHIP or participation as an EXHIBITOR has demon-strated its potential to help your sales and it is contributing to the strength and success of our industryas a whole.

We urge you to join us at THERMOFORMING 2006 in Nashville! Reserve your space early toavoid disappointment. Booth assignments are made on a first come, first serve basis.

Should you have questions, please call (706) 235-9298, fax (706) 295-4276or e-mail to [email protected].


EXHIBIT GUIDELINESEXHIBITOR PACKAGE: $2,250

10' x 10' Booth, Piped, Drape, Sign and Carpet provided.Additional booth spaces: 2nd $2,000, 3 or more $1,750 each.

All Exhibit packages include the cost of (1) Full Conference registration whichincludes all meals to a company representative. One is given for each boothpurchased. All additional attendees must be registered and pay full confer-ence registration to staff your exhibit.

Exhibitors must arrange for any additional services or needs in advance withthe designated decorating service. Exhibitor packet will be sent no later thanJune 1st, 2006.

Parts Competition and Plastics Van to be located in Exhibit area.

Ribbon Cutting Opening Exhibits on Sunday, September 17th, 2006 followedby Welcome Reception on Exhibit floor.

DEADLINE FOR CANCELLING EXHIBIT SPACE WITH REFUND IS JUNE 1st,2006. No refunds available after June 1st, 2006.


2006 THERMOFORMING CONFERENCE

Creativity & Innovation in Thermoforming

September 17th - 20th, 2006Nashville, Tennessee

EXHIBITOR REGISTRATION FORM(Please complete and return with your check today.)

_______ YES, we want to be a 2006 Thermoforming Exhibitor. Enclosed is our check for $2,250.Additional 10' x 10' booths as needed will be 2nd $2,000, 3 or more $1,750 each. Wewill require _________ Booths. We understand that space assignments will be assignedafter Sponsors have been selected. Cancellations will be accepted up to June 1st, 2006.

COMPANY NAME: _______________________________________________________________

CONTACT: ________________________________ SIGNATURE: _________________________

ADDRESS: ______________________________________________________________________

CITY/STATE/ZIP: ________________________________________________________________

PHONE: ________ FAX: _______________________E-MAIL:_____________________________

To properly plan exhibit or badge needs, please list everyone who will be attending. For eachexhibit space purchased, a complimentary registration is included ($295 value). All other per-sons must be registered for the full conference which includes all meals.

Name: ________________________________ Name: _________________________________

Name: ________________________________ Name: _________________________________

MAKE CHECKS PAYABLE TO: 2006 SPE THERMOFORMING CONFERENCE

MAIL TO: GWEN MATHIS, CONFERENCE COORDINATORSPE THERMOFORMING DIVISIONP. O. BOX 471, 124 AVENUE D, SELINDALE, GEORGIA 30147-0471FAX (706) 295-4276


2006 Thermoforming ConferenceEXHIBITORS

(Signed Up at Press Time)

“Creativity & Innovation in Thermoforming”* DENOTES 2006 SPONSORS

If your company name is not listed here, please get your form in to reserve your space. Contact Gwen Mathis at 706.235.9298.

COMPANY* Alcoa Kama Corporation* Allen Extruders* American Tool & Engineering,

Inc.* Aristech Acrylics LLC* Brown Machine LLC* Castek Aluminum* Ensinger/Penn Fibre* ExTech Plastics* Geiss Thermoforming USA LLC* Kiefel Technologies, Inc.* Klockner Pentaplast* Land Instruments International* Maac Machinery Company* New Hampshire Plastics* Onsrud Cutter* Plastimach Corporation* Portage Casting & Mold, Inc.* Premier Material Concepts* Primex Plastics Corporation

COMPANY* PTi (Processing Technologies,

Inc.)* Producto Company* Raytek Corporation* Robotic Production Technology* Sencorp, Inc.* Senoplast USA* Society of Plastics Engineers* Spartech Plastics* Stopol, Inc.* Thermoformer Parts Suppliers* Thermwood Corporation* Tooling Technology LLC* Total Industries International** Zed Industries


2006 THERMOFORMING CONFERENCECreativity & Innovation in ThermoformingTentative Technical Program Announced

Nashville Convention Center

MONDAY,SEPTEMBER 18th, 2006

Mini-Seminar in Advanced Topics inThermoforming - 3 Hours (Limited to 25attendees) - Dr. James Throne, SherwoodTechnologies, Inc.

This 3-hour advanced seminar is designed for thetechnologist who needs to know how the major engineeringaspects such as heat transfer, rheology, interfacial mechanics,and fracture mechanics are applied to thermoforming.

Attendees should consider this as a graduate-level seminarthat assumes a thorough undergraduate working knowledge ofengineering concepts and mathematics through calculus. If youdo not have this background, do not attend.

Please note that attendance is restricted to 25. A waiting listwill be available for late registrants.

There will be no handout. Attendees may download theinstructor’s PPT slides via their personal memory sticks at theend of the seminar.

Not all topics given in the following list will be covered,additional topics may be added, and those that will be coveredwill be at the discretion of the instructor.• The Technology of Sheet Heating

– Understanding the Fundamentals Behind the EnergyDome

– Radiant Transparency– Heating Sagging Sheet

• Mechanics of Sheet Stretching– Elastic Modulus and the Forming Window– Catenary and Elliptical Catenoid Models for Sag– K-BKZ Model – What and Why?– Melt Strain Hardening and the Stress Growth Function– Finite Element Analysis and Other Methods of

Determining Wall Thickness• Mechanics of Plug Assist

– Plane Strain vs. Biaxial Strain– Plug-Sheet Interfacial Concerns

• Trimming as Fracture Mechanics

“Development in Infrared Lamp Technologyfor Thermoforming” - Jerome Martinache,ITM-Application Group Leader, PhillipsSpecial Lighting

“Match Metal Trim for Thin Gauge” - BillHilts, Ontario Die Corporation

“Technology Does Not Have to beExpensive” - Scott Crandall, Director of

Quality & Advanced Technology, McClarinPlastics, Inc.

“Mold Temperature Control” - TBD

“Legislative Update” - TBD

“Business/Casualty Insurance Issues in theThermoforming Industry” - TBD

“Product/Company Branding” - TBD

“Innovation: The Risks and Rewards” - TBD

“Global View of the Resin Market” - TBD

TUESDAY,SEPTEMBER 19th, 2006

“Improving the Thermoformability ofPolypropylene by Modification of the CrystalPhase” - Dr. Phil Jacoby, Vice President ofTechnology, Mayzo Corporation

“Trends in Thermoform-Tooling in Europe” -Hubert Kittelmann, Marbach

“Heaters: How, When, Cost” - Frank Wilson,WECO and Ceramicx - Ireland

“Measuring Plug to Sheet InteractionsDuring the Thermoforming Process” - NoelTessier, CMT Materials; Tom Gallagher,Sunoco Chemicals

“Bio-Materials Outlook” - TBD

“Bringing PHB to the Plastics Industry: ANew Family of High PerformingEnvironmentally Friendly Plastics” - DanielGilliland, Metabolix


Workshops2006 Thermoforming Conference

Nashville, Tennessee** Attendees can only select one of the four workshops being offered.

You must register for the conference to attend workshops. **

SUNDAY,SEPTEMBER 17th, 2006

RENAISSANCE HOTEL - MUSIC CITY BALLROOM

8:30 a.m. - 3:00 p.m. – McConnell -Buckel Cut Sheet Workshop

I. INTRODUCTION• Advantages and Disadvantages of the

Thermoforming ProcessII. HEATING REQUIREMENTS

A. The Thermoforming Environment• Plant & Warehouse• Machine Locations• Environment Around Machines

B. Types of Heat – Advantages &Disadvantages• Convection• Conduction• Radiation• How to Obtain Uniform and/or Profiled Sheet Temperature• “K” Factors and Relative Rates of HeatTransfer• Regrind & Heat

III. VACUUM & COMPRESSED AIR SYSTEMSC. Vacuum Requirements

• Why Fast Vacuum Needed• Vacuum Pressure Measurements• Surge Tanks

D. Compressed Air RequirementsE. Hydraulic Platens

IV. FORMING TECHNIQUES – BASICTHERMOFORMING METHODSA. Vacuum Forming

B. Pressure FormingC. Mechanical FormingD. Prestretch Forming – For Better Material

Distribution• Vacuum Snapback• Plug Assist• Chamber Forming

E. Twin Sheet FormingF. WRAP UP

Limited to 150 - you must register to attend.

RENAISSANCE HOTEL - FISK ROOM

9:00 a.m. - 4:00 p.m. – Throne Roll FedWorkshop

This basic workshop introduces the various aspectsof thin-gauge thermoforming, from materials to ma-chinery, from processing aspects through trimming,to part and old design. A workshop notebook willbe provided.

The following will be discussed:

1. General aspects of thin-gauge thermoforming 2. Machine elements 3. Materials

PolymersAdditives

4. New materials to be consideredBiopolymersNanocomposites

5. The importance of sheet extrusion parameters 6. Heating the sheet 7. Forming the sheet 8. Trimming 9. Molds and mold design

Mold materialsPlug materials

10. Part design conceptsWall thickness determinationCornersCoiningPlug design

Art Buckel

Bill McConnell





11. Regrind considerations12. Foam forming13. Production monitoring and control

TemperanceBirefringence

14. Lingering concerns

James L. Throne: Jim Throne is Presi-dent, Sherwood Technologies, Inc.,Dunedin, FL., a consultancy focusingon advanced plastics processing tech-nologies, including thermoforming,foam processing and rotational mold-

ing. He is Fellow of the SPE and Fellow of IoM3 (En-gland). He was SPE Thermoformer of the Year 2000.He was honored by the SPE EuropeanThermoforming Division 2004 for his technical con-tributions to the worldwide thermoforming indus-try. He has published 10 books in polymerprocessing, including four in thermoforming. Heholds nine U.S. patents, including a fundamentalone in thermoforming CPET. He has written morethan a dozen technical book chapters and has pub-lished and presented nearly 200 technical papers.He is current Technical Editor of SPEThermoforming Quarterly. He is Fellow of the Soci-ety of Plastics Engineers and Fellow of Institute ofMaterials, Mining and Manufacturing (IoM3).


RENAISSANCE HOTEL - BELMONT ONE ROOM

9:00 a.m. - 12:00 p.m. – ProcessControls Workshop - “ImproveProduction Capacity of YourEquipment: Use Updated Controls”Thermoformer life can be extended and better-qual-ity product can be produced with updated controlsystems. Learn how temperature, gauge, speed, pres-sure and downstream equipment can all run basedon a product code, with adjustments made automati-cally based on set points and closed-loop control

algorithms (including shot cycle, platen movement,gauge/profile and temperatures). Your firm can re-duce scrap, boost throughput, improve quality andconsistency with improved controls and by identi-fying changes with trend charts/graphs and alarm-ing. Data collection is also useful for on-line trouble-shooting/diagnostics. This seminar will show youhow.

Michelle Curenton: Michelle currentlyserves as a Sales/Product Engineer withFACTS, Inc., a supplier of closed-loopcontrols systems for extruders, mixers,calenders and thermoformers. She hasspent ten years with the company,

which exclusively serves the plastics and rubberindustries. During this time she has worked as aproject and process engineer, managed many start-up projects and custom installations, and routinelyhelps clients with trouble-shooting or diagnostic is-sues. She is often called upon to support the com-pany with technical presentations and has presentedseveral papers at industry conferences and SPE meet-ings. Michelle holds an electrical engineering de-gree from The University of Akron. Prior to joiningFACTS, she worked for a leading company in thesteel industry in several engineering roles. In addi-tion to electrical/project engineering skills, she hasa strong IT background and combines process datawith a clear understanding of software/hardware ca-pabilities, including ERP and SPC applications. Shespecializes in identifying clients’ processing issuesand providing realistic solutions for improved tech-nology and manufacturing practices. Michelle ismarried and the mother of a son. She resides in NEOhio and routinely travels the country to work withclients on a variety of integrated line-control projectsfor plastics or rubber manufacturing.



RENAISSANCE HOTEL - BELMONT ONE ROOM

1:00 p.m. - 4:00 p.m. – How to DoBusiness in India WorkshopThe global economy has mandated internationalpartnerships, India and China emerging as twostrong partners. It is in the best interest of our manu-facturing industry to at least be aware of what ishappening in India and to understand several waysin which we can do business together. The seminarwill cover issued related to doing business with/inIndia including but not limited to Reasons for Ex-ploring Business Opportunities in India, MarketOpportunities for U.S. Firms in India, State of In-dian Manufacturing, State of Indian Services Sec-tor, Business Destination - Economic and Political,India’s Socio-Cultural Heritage, Challenges to Do-ing Business in India, U.S. Perception of India’sFuture, Future Directions and India’s Economic Poli-cies, Etc. A few case studies will be discussed tolearn from experiences.

Dr. Promod Vohra: Dr. Vohra is thedean of the College of Engineering andEngineering Technology (CEET). Dr.Vohra is a graduate faculty and a fullprofessor in the Department of Tech-nology. Prior to becoming the dean he

was the associate dean for six years where he boostedenrollment in the college by 45 percent over the lastseven years. Before that he was the electrical engi-neering technology (EET) coordinator in the Depart-ment of Technology. Dr. Vohra, in addition to hav-ing a doctorate in Instructional Technology (withcognate in Industrial Engineering), has a Masters aswell as a Bachelors degree in Electrical Engineer-ing. The BS degree was earned from Delhi Collegeof Engineering, India and the latter two degrees wereearned at NIU in 1988 and 1993, respectively. Priorto coming to the field of academia, he worked inindustry (Philips) for five years as a technical sup-port engineer. He joined NIU in 1988 as a lecturer,became an assistant professor in 1993, an associateprofessor in 1995 and the associate dean in 1997.




His interest areas are digital systems, instruction de-sign, industrial training, new technologies and ap-plications of technologies. As the coordinator of theElectrical Engineering Technology (EET) program(1988-1995), he increased the program enrollmentmore than 800 percent, published several refereed ar-ticles and brought in about a million dollars worth ofequipment grants to develop and expand EET labo-ratories. He recently brought in software and othergrants worth approximately 22 million dollars. Dr.Vohra has been very active in university service andin regional and national professional committees/or-ganizations. He was the recipient of the 1988 Out-standing Young Alumnus Award in 1995, he wasgiven the Excellence in Undergraduate TeachingAward by Northern Illinois University and in 1996he received the Outstanding Professor Award in theregion (seven professional registrations such as a pro-fessional engineering (PE) and a senior certified in-dustrial technologist (CSIT).


Nashvi l le ScenesNashvi l le Scenes

GRAND OLE OPRY

COUNTRY MUSICHALL OF FAME& MUSEUM

JACK DANIELDISTILLERY



Nashville, Tennessee** Attendees can choose one only. **

WEDNESDAY,SEPTEMBER 20th, 2006

RENAISSANCE HOTEL - RYMAN ROOM

8:30 a.m. - 3:00 p.m. – Extrusion WorkshopPresented by the SPE Extrusion Division


☞ Extrusion Basics - Tim Womer, Xaloy

☞ Co-Extrusion - Gary Oliver, Cloeren

☞ Compounding Extrusion - Paul Anderson, Coperion; Charlie Martin,Leistritz

☞ Reactive Extrusion - Paul Anderson, Coperion; Charlie Martin, Leistritz

☞ Extrusion Troubleshooting - Mark Spalding, Dow Chemical

RENAISSANCE HOTEL - MUSIC CITY BALLROOM

9:00 a.m. - 12:00 p.m. – Geiss Workshop


☞ “The Future of the Thermoforming Industry” - Manfred Geiss & AlbertWoltron, Geiss USA


We invite you to participate in this year’s Thermoforming Parts Competition and Showcase.This important event is a part of our 2006 SPE Thermoforming Conference in Nashville,Tennessee, September 17th - 20th, 2006. In order to make this year’s Parts Competition and

Showcase the best ever, we need your support. Take advantage of this unique opportunity to supportyour industry, get in front of editors from major publications, and show off your thermoforming skills.

SHOWCASE OF PARTSThe Showcase of Parts was developed as a non-competitive forum to display products from our indus-try. This year’s showcase will feature past award winning parts, as well as parts not involved in thecompetition. We also encourage any thermoformer, machinery manufacturer, material supplier, andattendee to share parts with us. This will be a show and tell area for all to promote their parts. Items ofinterest in the industry like thermoforming versus other processes, new materials, or environmentalissues are encouraged. Do you have a success story to share with us?

Cut Sheet Parts CompetitionThe following Categories will be Judged:

AutomotiveConsumer ProductsTwin Sheet ProductMulti-Part AssemblyElectronic ProductsIndustrial ApplicationPoint of Purchase

16th Annual PartsCompetition and Showcase

BY JAMES ALONGI, PARTS COMPETITION CHAIRMAN

Roll-Fed Parts CompetitionThe following Categories will be Judged:

Consumer PackagingConsumer HousewaresCritical BarrierConsumer ElectronicsFood ContainerIndustrial Packaging

Best International Part

AdditionalAdditionalAdditionalAdditionalAdditionalCategories

CategoriesCategoriesCategoriesCategoriesmay be added

may be added

may be added

may be added

may be addedbased on parts

based on parts

based on parts

based on parts

based on partssubmitted.submitted.submitted.submitted.submitted.

AdditionalAdditionalAdditionalAdditionalAdditional

CategoriesCategoriesCategoriesCategoriesCategories

may be added

may be added

may be added

may be added

may be added

based on parts

based on parts

based on parts

based on parts

based on parts

submitted.submitted.submitted.submitted.submitted.


PEOPLE’S CHOICE AWARDThis award is voted on by the attendees and exhibitors of the SPE Thermoforming Conference. Ballots are pro-vided at the Conference registration and the ballot box is located in the Parts Competition Pavilion. One entryper person. The award is presented at the Parts Competition Awards Dinner on Tuesday, September 19th, 2006.

JUDGINGThe judging will be conducted by a panel of six industry professionals, from both the cut sheet and roll fedindustries. The judges will have extensive knowledge of all aspects of the thermoforming process. A minimumof 3 entries per category is required for an award to be presented.

JUDGING CRITERIAThe judging criteria will include technical mastery, surface finish, distinct quality, market viability (compared toother processes), originality, material difficulty, mold complexity, and secondary operations. All entries willremain anonymous until the judging is completed. A part and process write up will be allowed for the judging ifit does not include the name of the thermoformer. The parts will be judged based on the process and not the enduse of the products.

AWARDSAll participants and award winners will be recognized on Tuesday, September 19th, 2006 at the Parts Competi-tion Awards Dinner at the Renaissance Hotel.

For more information, contact: James Alongi(630) 665-1700 Fax (630) 665-7999


OFFICIAL ENTRY FORM

16th AnnualParts Competition and Showcase

❏ Parts Competition ❏ Showcase Entry

Company: _____________________________________________________________________________________

Address: _______________________________________________________________________________________

City: _______________________________ State: _________________Zip: ____________Country:_____________

Company Contact: ______________________________________________________________________________

Telephone: ___________________________________________ Fax: ______________________________________

E-mail: ________________________________________________________________________________________

Entry Specifications:Category: ❏ Cut Sheet ❏ Roll Fed

Parts Description: _______________________________________________________________________________

Material Type: _________________________________ Gauge: _______________Supplier: ___________________

Mold Construction: _______________________________________ Mold Builder: _________________________

Part Description and Unique Challenges for Consideration: __________________________________________

_______________________________________________________________________________________________

_______________________________________________________________________________________________

FOR SHIPMENT UP TO 30 DAYS IN ADVANCE OF SHOW:Please ship to: Roadway Express

c/o RPM / Complete Expo Parts Competition3240 Franklin-Limestone RoadAntioch, Tennessee 37013

• Please supply this form with a company labeled photo with each part entry.• A supplemental sheet can be provided to expand the part description/unique challenges section. Pleaserefrain from mentioning the company name in this section.• A faxed copy of your entry is required by August 21st, 2006 to Fax: (630) 665-7799.• CLEARLY LABEL EACH CARTON: SPE PARTS COMPETITION – DO NOT OPEN!• Parts will be accepted from August 21st to September 11th, 2006.• Judging will be done prior to opening of show – entries must be received prior to September 11th, 2006.IF YOU DESIRE TO HAVE YOUR PARTS RETURNED, YOU MUST PROVIDE PACKAGING AND EN-CLOSE A PRE-ADDRESSED RETURN LABEL AND PREPAID SHIPPING INSTRUCTIONS.

Signature: ________________________________________________________________ Date: _________________

For more information, please contact James Alongi, Maac Machinery, (630) 665-1700, Fax (630) 665-7799,or email: [email protected].


16th Annual Thermoforming Conference

For Reservations: Call 615.255.8400Request: SPE Thermoforming Rate

of $143.00

Check out our websites at:http://www.4spe.org/ communities/divisions/d25.php

www.thermoformingdivision.com

For Information Contact:

CONFERENCE COORDINATOR:GWEN MATHIS

706.235.9298 • Fax 706.295.4276E-mail: [email protected]

**Please note! The hotel will require a depositof one night’s room and tax at the time thereservation is made. Cancellations made afterAugust 13, 2006 will result in the forfeiture ofone night’s deposit. Any reservation madeafter August 13, 2006 will require a non-refundable one night’s deposit at the time thereservation is made.

September 17th – 20th, 2006Nashville Convention CenterRenaissance Nashville HotelNashville, Tennessee

1 Thermoforming QUARTERLY

Contents

Th e rmo f o rm i n g®

Q U A R T E R L Y

A NOTE TOPROSPECTIVE

AUTHORSTFQ is an “equal opportunity”publisher! You will note that we haveseveral categories of technical articles,ranging from the super-high tech(sometimes with equations!), toindustry practice articles, to bookreviews, how to articles, tutorialarticles, and so on. Got an article thatdoesn’t seem to fit in these categories?Send it to Jim Throne, Technical Editor,anyway. He’ll fit it in! He promises. [Bythe way, if you are submitting anarticle, Jim would appreciate it onCD-ROM in DOC format. All graphsand photos should be black and whiteand of sufficient size and contrast tobe scannable. Thanks.]

QUARTERLY

A JOURNAL PUBLISHED EACH CALENDARQUARTER BY THE THERMOFORMING DIVISION

OF THE SOCIETY OF PLASTICS ENGINEERS

EditorGwen Mathis

(706) 235-9298 • Fax (706) [email protected]

Technical EditorDr. James Throne

Sherwood Technologies, Inc.1797 Santa Barbara DriveDunedin, FL 34698-3347

1-800-273-6370 • Fax (727) [email protected]@tampabay.rr.com

SponsorshipsLaura Pichon

(815) 678-2131 Ext. 624Fax (815) 678-4248

[email protected] Quarterly® is published four times an-nually as an informational and educational bulletinto the members of the Society of PlasticsEngineers, Thermoforming Division, and thethermoforming industry. The name, “ThermoformingQuarterly®” and its logotype, are registered trade-marks of the Thermoforming Division of the Societyof Plastics Engineers, Inc. No part of this publicationmay be reproduced in any form or by any meanswithout prior written permission of the publisher,copyright holder. Opinions of the authors are theirown, and the publishers cannot be held responsiblefor opinions or representations of any unsolicitedmaterial. Printed in the U.S.A.

Thermoforming Quarterly® is registered in the USPatent and Trademark Office (Registration no.2,229,747).

These sponsors enable us to publish Thermoforming QUARTERLY

TECHNICAL SECTION

Chairman’s Corner .................................................................. Inside Front CoverMembership Memo: 10 Years – A Good Time to Reflect ................................. 2New Members ..................................................................................................... 3Spotlight on Industry: Placon Corp. .................................................................. 8Spring Board Meeting Schedule ........................................................................ 92006 Thermoforming Conference Registration Form.................................... 26Thermoforming Quarterly Index ..................................................................... 30Membership Application ................................................................................. 37Index of Sponsors ............................................................................................. 40Board of Directors List ............................................................. Inside Back Cover

Lead Technical Article:Novel Method For Rapid Determination of Thermoformability ................................. 10

Industry Practice:Heating Filled Plastics ..................................................................................................... 16

University News:Rose-Hulman Institute of Technology ........................................................................... 19

Industry Practice:History of Thermoforming – Part III ............................................................................... 21

Thermoforming 101:Draft Angles ..................................................................................................................... 23

Book Review:Measuring to Manage: Using Measurable Data to Get Maximum

Employee Performance ............................................................................................... 24

DIVISION ACTIVITIESThermoforming®

Thermoforming QUARTERLY 2

MEMBERSHIP MEMO

BY MIKE SIROTNAK, MEMBERSHIP CHAIRMAN

10 Years – A GoodTime to Reflect

MEMBERSHIP REPORTas of 1/4/06

Primary Paid .......................1,144

Secondary Paid ......................496

Total Membership ..............1,640

Goal as of 6/30/2007 .........2,000

I cannot believe that I havebeen a member of the SPE

Thermoforming Division for10 years and your Member-ship Chairman for 8 years.We have been through quitea bit in those years. We havehad some amazinghighs – Chicago in1999 – and some unfor-tunate lows – Milwau-kee in 2001. We havehad some outstandinggrowth in both ourConference attendanceand in the quality ofour Quarterly. We areoffering more scholar-ship and committingto more good deeds.Our industry seems to be re-ally taking off with advance-ments in automotive, medi-cal packaging and consumergoods. The future of theThermoforming Industrycontinues to look bright. Theonly way to keep up withthis fast-moving industry isto continue to support thisDivision.

The New Year will bringsome interesting challengesfor all of us. Our Conferencewill be held September 17th- 20th in Nashville, Tennes-see. I think Nashville is myfavorite location for our Con-ference. It has everything

you need, good food, greatmusic and plenty to see,right within walking dis-tance. Martin Stephenson isworking long hours to bringus a great Conference thisyear. The technical programis in the capable hands ofMike Lowery. I urge all ofyou to do anything you canto support this Conference.

If you have any suggestionson how to improve, grow orchallenge this Conference,please feel free to contact oneof us on the Board. Theamount of “good works” weare able to accomplish due toa successful Conference is

hard to believe. Pleasecontinue to supportus, so that we maycontinue to supportand grow our indus-try.

As always, I askeach and every one ofyou to continue tosupport membership.If you know of any-one who may benefit

from this Quarterly or fromany of the other advantagesthat membership offers,please let us know. Have agreat year and I hope to seeyou in Nashville.

God bless America!!


To Our New MembersRoger E. BlantonSpringfield,

Missouri

Thomas E. BrownAllen Extruders,

Inc.

Ron ConnellAlcoa Reynolds

FoodPackaging

Phillip CrosbieMarplexVictoria, Australia

Matthias H.Erhardt

Siemens Energy& Automation

Norcross, Georgia

Brian K. EvensonPlastica Plus, Inc.Brainard,

Minnesota

Eric FaucherMarquexz

TranstechMontreal, QC -

Canada

Ke FengGE PlasticsWashington, West

Virginia

Joe GreenManPlas, Ltd.Stockport, United

Kingdom

Jeff GriffinEviro Systems,

Inc.Seminole,

Oklahoma

Seref HaluluSaykap AsIkltell, Turkey

Howard J. KenneySpartech PlasticsClayton, Missouri

Youngseok SeiokKim

Mississauga,Ontario -Canada

Edward KusIntermatic, Inc.Spring Grove,

Illinois

Niall MarshallKamption GateSouth Africa

Steven L. MasiaSAPPI Fine PaperWestbrook, Maine

Jason N. MattiaAlcoa KamaHazleton,

Pennsylvania

Atul MehtaNew Berlin,

Wisconsin

StephanieMorgan Fisher

Stanelco, Inc.Orlando, Florida

Richard MotillProex, Inc.Batavia, Illinois

Paul J. NicholsonSignum NZ Ltd.Greenmount,

New Zealand

WHY JOIN?It has never been more important to be a member of your professional societythan now, in the current climate of change and volatility in the plastics industry.Now, more than ever, the information you access and the personal networks youcreate can and will directly impact your future and your career.

Active membership in SPE:• keeps you current

• keeps you informed• keeps you connected

The question really isn’t “why join?” but …

WHY NOT?

Thomas S.Pedersen

Rexam PlasticsContainers

Skanderborg,Denmark

Mark RathReynolds Food

PackagingGrove City,

Pennsylvania

Doug SheltonMcConkay

CompanySummer,

Washington

Benjamin W.Smith

Devon,Pennsylvania

Paul W. TomichFirst Choice

PackagingFremont, Ohio

Bill TrometerAsheville

ThermoformPlastics

Fletcher, NorthCarolina

Frank TuckerAls Garden Art

Pty Ltd.Gold Coast,

Australia

David VadneyPactivCanandaigua,

New York


2005 THERMOFORMING PARTS COMPETITION WINNERSR E T R A C T I O N

We sincerely apologize to Perfecseal, Prent Corporation and Profile Plastics for errors in the Parts Com-petition Section that were published in the 4th Quarter Thermoforming Quarterly. We regret our mistakesand wish to issue the correct information. ~ Editor

Critical Barrier Package AwardThe redesign of

packaging for twomedical devices, asling system and asubfascial hammock,was initiated in orderto reduce the size of the packaging and to make itpossible to denest the trays without the occurrenceof tissue interleafing. By rearranging the orientationof the devices, Perfecseal was able to achieve tray-volume reductions of 68% for the sling system and54% for the subfascial hammock. Additionally, byusing C0025 Internal Denest PETG supplied by Pacur,Inc., Perfecseal was able to eliminate the problem oftissue interleafing without requiring a revalidationof the seal parameters, which would have been nec-essary if a silicone-coated material had been choseninstead.Perfecseal (A. Demis Co.); 920.303.7129www.perfecseal.com

Consumer Electronics AwardThe packaging for Western

Digital’s Portable USB Drive isa unique set of fourthermoforms, each with a spe-cific role to play in creating thepackage. Two static dissipativeinner thermoforms snap to-gether to secure the hard driveinside trays that are sealed to-gether using radio frequency(RF). The inner parts are madefrom 0.020-inch clear Pentastat ASKPET 56 suppliedby Klockner Pentaplast of America, Inc., and the traysare made from 0.030-inch clear GAG supplied by ThaiKodama Co. Ltd. ASKPET 56 offers ESD protectionfor the actual product, and the use of GAG providesthe ability to RF seal. This 100% recyclable plasticdesign meets product-protection requirements whileproviding product visibility, ESD protection, andshelf appeal. The packages, which afford both frontand back views of the product, require less shippingspace because they interlock when every other one

is rotated 180° in the shipping carton.Prent Corporation; 608.754.0276; www.prent.com

Roll Fed CompetitionMost Unique Package Award

The DePuy OrthopaedicsTempfix External Fixation Sys-tem package consists of five in-dividual thermoformed parts.Each of three modular innertrays carries one of four differ-ent fixation devices, along withthe tools for their application.One universal cover snap-fits onto each of the modu-lar inner trays, while one universal outer tray holdsand protects any of the inner/cover combinations.Each product tray with cover is loaded into the seal-able outer tray for sterilization. The cover providesan area for a graphic feature. All inner trays and coverare formed from .040 Blue Tint PETG. The outer trayis formed from .045 Blue Tint PETG Goex Corp. sup-plies the materials.Prent Corp., 608.754.0276; www.prent.com

Multipart AwardThe panoramic analog dental X-ray

enclosure required a total of nine parts(12 parts for the digital model), all ofwhich were pressure formed into ma-chined aluminum water-cooled, tex-tured molds. The texturing of moldsallows for a consistent part finish forall parts and eliminates evidence ofsink marks, knit lines, and gate marksthat are typically associated with injection molding.Clean part-to-part fit is accomplished with undercutsin the molds, which are pneumatically articulatedwith solenoids tied into the digital programming logicof the forming machines. Because of the ellipticalcontours of the enclosure’s design, the undercuts arebroken into multiple sections for each side of theparts. Tight process control of molded-in color andtexture for consistent part-to-part appearance wasrequired. The material used was 0.187 to 0.375 gaugeKydex T, supplied by Kleerdex Co.Profile Plastics; 847.604.5100; www.thermoform.com


These sponsors enable us to publish Thermoforming QUARTERLYNeed help withyour technical

school orcollege

expenses?

If you or someone youknow is working

towards a career in theplastic industry, let the SPEThermoforming Divisionhelp support thoseeducation goals.

Our mission is tofacilitate the advancementof thermoformingtechnologies througheducation, application,promotion, and research.Within this past year alone,our organization hasawarded multiplescholarships! Get involvedand take advantage ofavailable support from yourplastic industry!

Start by completing theapplication forms atwww.thermoformingdivision.comor at www.4spe.com. Thedeadline for applications isJanuary 15th, 2007. ■

Thermoforming & Extrusion Consultants Manufacturing Processes Analysis

Product & Design Development Training & Seminars

PH:843.971.7833 · Fax: 843.216.6151 On the Web at www.plasticoncepts.com

443 Long Point Rd Ste H · Mt. Pleasant · SC · 29464-4569


THERMOFORMER OF THE YEARCRITERIA FOR 2007

Every year The SPE Thermo-forming Division selects a indi-

vidual who has made a outstand-ing contribution to our industry andawards them the Thermoformer ofthe Year award.

The award in the past has goneto industry pioneers like Bo Strattonand Sam Shapiro, who were amongthe first to found thermoformingcompanies and develop our indus-try. We have included machine de-signers and builders Gaylord Brownand Robert Butzko and toolmakerJohn Greip, individuals who helpeddevelop the equipment and moldideas we all use today. We havealso honored engineers like LewBlanchard and Stephen Sweig, whodeveloped and patented new meth-ods of thermoforming. Additionally,we have featured educators like BillMcConnell, Jim Throne andHerman R. Osmers, who have bothspread the word and were key fig-ures in founding the ThermoformingDivision.

We’re looking for more individu-als like these and we’re turning tothe Thermoforming community tofind them. Requirements would in-clude several of the following:

➢Founder or Owner of aThermoforming Company

➢Patents Developed

➢ Is currently active in or recentlyretired from the ThermoformingIndustry

➢ Is a Processor – or capable ofprocessing

➢Someone who developed newmarkets for or started a newtrend or style of Thermoforming

➢Significant contributions to thework of the ThermoformingDivision Board of Directors

➢Has made a significant educa-tional contribution to theThermoforming Industry.

If you would like to bring some-one who meets some or all of theserequirements to the attention of theThermoforming Division, please fillout a nomination form and a one-to two-page biography and forwardit to:

Thermoforming Division AwardsCommittee% Productive Plastics, Inc.Hal Gilham103 West Park DriveMt. Laurel, NJ 08045Tel: 856-778-4300Fax: 856-234-3310Email:[email protected]


You can also find the form and see all the past

winners at www.thermoformingdivision.com in

the Thermoformer of the Year section.

You can submit nominations and bios at any time

but please keep in mind our deadline for

submissions is no later than December 1st of

each year, so nominations received after that

time will go forward to the next year.


THERMOFORMER OFTHE YEAR 2007

Presented at the September 2007 Thermoforming Conference in Cincinnati, Ohio

The Awards Committee is now accepting nominations for the 2007THERMOFORMER OF THE YEAR. Please help us by identifying worthy candidates.This prestigious honor will be awarded to a member of our industry that has madea significant contribution to the Thermoforming Industry in a Technical, Educa-tional, or Management aspect of Thermoforming. Nominees will be evaluatedand voted on by the Thermoforming Board of Directors at the Winter 2007 meet-ing. The deadline for submitting nominations is December 1st, 2006. Please com-plete the form below and include all biographical information.

Person Nominated: _______________________________________ Title: _____________________

Firm or Institution: _________________________________________________________________

Street Address: _____________________________ City, State, Zip: ________________________

Telephone: _________________ Fax: _________________________ E-mail: _________________

Biographical Information:

• Nominee’s Experience in the Thermoforming Industry.

• Nominee’s Education (include degrees, year granted, name and location ofuniversity)

• Prior corporate or academic affiliations (include company and/or institu-tions, title, and approximate dates of affiliations)

• Professional society affiliations

• Professional honors and awards.

• Publications and patents (please attach list).

• Evaluation of the effect of this individual’s achievement on technology andprogress of the plastics industry. (To support nomination, attach substan-tial documentation of these achievements.)

• Other significant accomplishments in the field of plastics.

• Professional achievements in plastics (summarize specific achievements uponwhich this nomination is based on a separate sheet).

Individual Submitting Nomination: _______________________ Title: _____________________

Firm or Institution: _________________________________________________________________

Address: ____________________________________ City, State, Zip: ________________________

Phone: ____________________ Fax: _________________________ E-mail: _________________

Signature: ______________________________________ Date: ____________________ (ALL NOMINATIONS MUST BE SIGNED)

Please submit all nominations to: Hal Gilham,Productive Plastics, 103 West Park Drive

Mt. Laurel, New Jersey 08045

Thermoformers of the Year …1982

William K. McConnell, Jr.McConnell Company

1983E. Bowman Stratton, Jr.

Auto-Vac Corp.

1984Gaylord Brown, Brown Machine

1985Robert L. Butzko,Thermtrol Corp.

1986George Wiss,

Plastofilm Industries

1987Dr. Herman R. OsmersEducator & Consultant

1988Robert Kittridge

Fabri-Kal Corporation

1989Jack Pregont, Prent Corporation

1990Ripley W. GageGage Industries

1991Stanley Rosen

Mold Systems Corp.

1992Samuel ShapiroMaryland Cup

Sweetheart Plastics

1993John Grundy

Profile Plastics

1994R. Lewis Blanchard

Dow Chemical

1995James L. Blin, Triangle Plastics

1996John Griep

Portage Casting & Mold

1997John S. Hopple, Hopple Plastics

1998Lyle Shuert, Shuert Industries

1999Art Buckel, McConnell Company

2000Dr. James Throne

Sherwood Technologies

2001Joseph Pregont, Prent Corp.

2002Stephen Sweig, Profile Plastics

2003William Benjamin

Benjamin Mfg.

2004Steve Hasselbach, CMI Plastics

2005Manfred Jacob

Jacob Kunststofftechnik


PLACON CORPORATIONSPOTLIGHT ON INDUSTRY

Placon Corporation, now inits 40th year, was the dream

and is still the passion ofentrepreneur and engineerTom Mohs.

Headquartered in Madison,Wisconsin, Placon is a globalthermoformer, supplyingcustomers on four continentswith well-designed, quality

manufactured thermoforms.Placon services its globalcustomers from three facilities –Madison, WI; Loves Park, IL; andSuzhou, China.

Company revenues exceeded$85 million in 2005 through theefforts of nearly 350 teammembers.

Tom Mohs, who today is thecorporation’s Chairman, is one ofthe industry’s originalentrepreneurs. Tom’s keeninterest in plastics and plasticsprocessing were evident early onin his life when he led an effortas a student at the UW -Madison’s College of Engi-neering, to convince the Dean tosupport a plastics processingcourse in its curriculum and hesucceeded.

After graduation, Tom went towork in product developmentwith the Plax Corporation inConnecticut. There, he appliedhis plastics processingknowledge and design skills tocreating new products,particularly thermoformedplastic products. Tom was one ofthe original developers of thethermoformed high impactpolystyrene dairy container andlid.

Always having had an interestin starting his own enterprise,

Tom decided after four years toreturn to his hometown and starta custom thermoformingbusiness. He had a lot of ideasfor new thermoformed productsand focused on designing themto efficiently serve theirfunctions. He brought revolu-tionary ideas to product andtooling design, thermoformerdesign and processing. He tookon the tougher designapplications and put forth theeffort needed to further thecapabilities of the industry.

Today, the company’s tagline“Better Design. Better Packaging.”ensures the original intent of itsfounder.

Placon remains privately heldby Tom and his family, and staystrue to its founder ’s solidMidwestern values. Tom’sgreatest desire is that Placonteam members can feel proud towork at Placon and, as a resultof being part of the organization,can achieve their own personaldevelopment and success.

Placon today is a thrivingcorporation listed in the top 20in thei n d u s t r yand isd r i v i n gtoward itsgoal tobecome aTop 10N o r t hA m e r i c a nT h e r m o -former by2010. Ina c h i e v i n gthis goal, thec o m p a n y

believes it will position itselfto be able to remain privately-held and continue todetermine its own destinythrough the next generation.

Placon’s primary marketsare in food, retail and medicalpackaging. The companycontinues to invest in theindustry’s latest technologies in equipment and operatingsystems, so that it is capable ofcontinuing to offer its customerswhat they need to succeed andlead in their markets.

Placon will continue to expandgeographically to support itscustomers’ regional needs.Placon opened its first operationin China in December of 2004 toservice its retail customer basewho, to remain globallycompetitive, had to move theirmanufacturing operations toAsia. Outside of Madison andLoves Park, Placon expects tocontinue its geographicexpansion in North America inthe upcoming years before 2010.

■


These sponsors enable us to publish Thermoforming QUARTERLYTHERMOFORMINGDIVISION

SPRING BOARDMEETING SCHEDULE

May 3rd - 7th, 2006Hilton Oceanfront Resort

23 Ocean LaneHilton Head, South Carolina

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Wednesday, May 3rd, 2006Executive Committee ArriveTechnical Chairs Arrive

Thursday, May 4th, 20067:30 am – 8:00 am – Breakfast8:00 am – 10:00 am – Technical Chairs

Meet with Executive Committee10:00 am – 5:00 p.m. – Executive

Committee Meeting11:00 am – Noon – James Alongi,

Finance Committee Meet withExecutive Committee

Friday, May 5th, 20069:00 am – 11:00 am – Materials

Committee - Promenade 19:00 am – 11:00 am – Machinery

Committee - Promenade 89:00 am – 11:00 am – Processing

Committee - Captain’s Galley A12:00 pm – 1:00 pm – Lunch - Captain’s

Galley B1:00 pm – 5:00 pm – All Other

Committees - Captain’s Galley B6:00 pm – Board Dinner Off Site - TBD

Saturday, May 6th, 20067:30 am – 8:30 am – Breakfast –

Promenade 88:30 am – Noon – Board of Directors

Meeting - Promenade 6-7Golf to be arranged by Joe Peters

Sunday, May 7th, 2006Depart

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LEAD TECHNICAL ARTICLE

Novel Method For Rapid Determinationof Thermoformability1

BY A. DHARIA, TRANSMIT TECHNOLOGY GROUP, LLC, IRVING, TEXAS andD. HYLTON, MCCONNELL CO., INC., FAIRBURN, GEORGIA

1 Ed. Note: This article was presented at ANTEC 2005. It has beenretyped and edited from the ANTEC Proceedings paper. Anyerrors, omissions or commissions are solely the responsibility ofthe Technical Editor.

AbstractThe demand for large parts with thick walls,

constructed of multiple polymer layers, along withthe desire for quick turn-around time, lower toolingcost, and low-pressure processing is makingthermoforming very attractive v. injection molding.Despite the long history, thermoforming is still verymuch an art rather than a science. There are veryfew reliable tests available to processes andresearchers for analyzing and quantifyingthermoformability. This paper presents acomparison between current methods and a noveltest apparatus that closely simulates thethermoforming process under controllableconditions while collecting quantitativeinformation, which can be used to assess, compare,optimize, or predict thermoformability of givenplastic materials.

IntroductionThermoforming is a widely used process to

produce deep arts of various wall thickness andsurface textures. Production is very cost-effectivewith respect to tooling and machine costs andmodern machines can achieve high output rates.In principle, thermoforming is a simple process ofstretching heating plastic sheet over or into a moldcavity. Theoretically, the ability of a plastic materialto be shaped by thermoforming depends on the rateof change of strength or modulus with the changein strain rate and temperature (1). In reality, theprocess is a complex interplay between polymermolecular weight (MW), molecular weight

distribution (MWD), crystallinity, density, thermalconductivity, and temperature-dependent meltviscosity and melt elasticity. Another variable,which may influence thermoformability, is theprocessing history of the extruded sheet stock. Thelarger the part and the thicker the wall become, themore complex is the effect of these factors duringand after the forming process. Significant hands-on experience is required to make new polymericmaterials work.

Unlike other processes, thermoforming requiresflat sheet, not pellets, as feedstock. So any materialintended for thermoforming must be first convertedinto sheet. Depending on the process of makingsheet, process conditions, process rates, amount ofregrind, and storage conditions, the feedstock mayvary in its thermal stress distribution, within andbetween lots. This can create a real blind spot, whichconverters overcome by on-line adjustment of thethermoforming process parameters. The situationcan be even more complex if the extruded sheetconsists of more than one plastic, with dissimilarnatures, or with one side of the sheet grained ortextured. For most other processes, judicious useof the simple melt flow rate test can help processorssolve many of the processing and quality relatedissues.

This is not the case with thermoforming. Actualdetermination of thermoformability through fieldtrials can be very expensive. What test will one useto make sure whether or not a new material willthermoform satisfactorily? How does one learnabout lot-to-lot or within-lot variations? How doesone accommodate known variations? There is noeasy-to-use, repeatable, yet comprehensive test torescue converters, especially when a new materialor supplier is involved.

Several tests (2) are available, some of which arevery crude, qualitative, easy to understand but not


.

(continued on next page)

repeatable. Others are highly analytical, expensiveand difficult to comprehend. The following is areview of some of these tests.

Sag test (3). Sag is the temperature-dependentmeasure of tensile strength and sheet geometry.This is the most commonly used test, whichsimulates hot creep under no external load. A flatsheet is clamped in a frame and heated to a formingtemperature inside a forced air oven or by radiantheaters. The time required for the heated sheet tosag to a fixed distance is reported as sag resistance.This test is a useful first step but the results dependon how the sample is clamped (circular window v.rectangular window, cantilever v. all sidesclamped), sheet weight, method of heating, surfacearea, and sheet thickness. It is often not repeatableand does not provide any clue about melt elasticity,i.e., how the heated sheet will react to externalstresses in, say, plug-assisted forming. The plasticmay have a very high sag resistance but may haveno ability to form at all.

Hot tensile/creep test (4). As the polymertemperature increases, its strength and modulusdecrease and elongation increases. Thermoformingoccurs in the rubbery plateau, at temperaturesabove the glass transition temperature, Tg. Thebroader the rubbery plateau and the higher thepolymer modulus at the forming temperature, thebetter the thermoformability. In this test, a specimenis die-cut from the extruded sheet. It is heated tothe desired temperature in a forced airenvironmental chamber and is stretched at constantspeed. The tensile modulus or strength is plottedagainst strain. Even though quantitative in nature,hot tensile tests are difficult to carry out with anydegree of reliability. At elevated temperatures,stretching is not confined to the neck-down portion,and grip-slip or grip-extrusion is common. Slowheating rates may induce annealing.

Hot creep tests are more sensitive than hot tensiletests to changes in polymer character. Further, heatis conducted to the load cell, affecting the accuracy.

Neither test truly replicates biaxial stretchingunder rapid speed (>20 mm/sec), and heat transferbetween the mold and the heated plastic sheet thatis so common even in the simplest thermoformingprocess is not present in either test.

Dynamic rheological tests. Dynamic mechanicaltesting is used to determine the storage or elastic

modulus (G’) and the loss or viscous modulus (G”)as functions of temperature or strain rate. This testrequires less material than those given above, canbe done rapidly, and the results are highlyrepeatable. The data provide indirect informationabout MD and MWD, as well as direct informationof the complex modulus as a function oftemperature (5). Higher zero shear viscosity,broader MWD, and higher modulus at the formingtemperature are considered to be favorableattributes of a polymer. However, the testequipment is expensive and requires a trainedperson to run the test and interpret the data. Mostimportantly, it does not reflect the variables in thethermoforming process.

The thermoforming process can be simulatedthrough the stress relaxation experiment (6). In thistest, stress is applied to the plastic and the decay instress relaxation is measured. Stress relaxation timeis reported to increase linearly with sag resistance(5). However, at elevated temperatures at high-applied stress levels, the creep rates are very high,making interpretation of the creep data difficult.In addition, the stress relaxation constant varieswith the test parameters selected.

Melt tension test. In this test, the plastic is melted,extruded into a fiber, and the fiber is stretched atconstant velocity. One device that performs this testis the Rheotan attached to a capillary rheometer.The test is repeated at various velocities. The forceand velocity at which the fiber breaks are reportedas melt strength and draw velocity. Even thoughthis test is useful, it is not very representative ofthe thermoforming process. First, the process isdone above the melt temperature of the polymer,while most thermoforming is done in the rubberyregion of the polymer. Thus, all information relatingto sheet extrusion parameters are lost during themelting step. Fiber is one-dimensional while thinsheet is two-dimensional and thick sheet is three-dimensional. The draw strength and velocity canvary with the way in which the fiber is cooled.Further, some plastics tend to strengthen bystretching in one dimension. This is a simple testand results are easy to interpret, but the data donot correlate well with the forming processvariables.


Figure 1. Thermoformability Analyzer9.

(continued from previous page)

Numerical methods (7). There are computationaltools which numerically simulate thermoformingand predict response to input variables. However,these methods, like most numerical simulationmethods, are based on simplified assumptions, andrequire values of many polymer characteristics,many of which are not readily available or areexpensive to obtain. The free surface flow involvedand the complexity of modeling melt elasticitymake these models less reliable.

In absence of any real, easy-to-use and easy-to-interpret test method, one must resort to actualthermoforming. This may require a large amountof plastic sheet, time, and money. Results of onetrial may not always be applicable to actualproduction. Therefore, we propose a method thatovercomes many of these obstacles.

Proposed EquipmentAs shown in Figure 1, the proposed automated

equipment is a miniature version of actualthermoforming machine and incorporates allessential unit steps – heating, forming, and cooling.It uses 4-inch x 4-inch square sample of desired

rate, heat soak time, ram speed, cooling time,maximum force, and the maximum draw depth.Once activated, the sample tray moves to theheating station where two infrared or ceramicheaters heat the sample from above and below. Bothheaters can be programmed independently and canbe positioned at desired distances from the samplesurfaces. A non-contact, laser-guided infraredtemperature probe continuously measures thesurface temperature.

When the sheet reaches the preset surfacetemperature, or the preset temperature and heatsoak time, the tray moves to the forming station inless than a second. A plunger, equipped with a maleplug descends into the sheet at a preprogrammedspeed. The force required to deform the heatedsheet is continuously measured by a load cellmounted on the top of the plug. The computerinterface captures the force data and plots it as afunction of either the distance from the surface ortime.

As soon as either the preset force is reached orthe sheet is deformed to a preprogrammed distance,a fan is activated to cool the sample for apreprogrammed time. At the end of the coolingtime, the plunger retracts and the tray carrying thecold, formed part is returned to the loading station.The part is then manually removed from the tray,inspected for wall thinning, tearing, blisters, burnmarks, loss of grain or texture, loss of gloss, fading,and so on. Thickness is manually measured andthe thickness distribution recorded.

The equipment and software allow selection ofpressure forming, vacuum forming, or vacuum-assisted pressure forming.

The force data can either be used as is or withsuitable software, can be converted into a predictivemodel.

The equipment overcomes several problems ofearlier methods:

• It uses a small amount of sample, either fromexisting feedstock or made using availablequality control equipment.

• It heats material rapidly but under controllableconditions. This allows mimicking actualthermoforming conditions. Further, the top andbottom of the sheet can be heated to differenttemperatures either by adjusting the distance

thickness, preferably die-cut from extrudedfeedstock, but it can also be injection or compressionmolded. Most quality control labs have 8-inch x 8-inch heated compression presses and injectionmolding machines. The sample is clamped betweentwo insulated plates, and the tray is manuallyplaced on the loading rail.

A software input menu includes the selection ofthe forming method, forming temperature, heating


Figure 2. Forming force vs. draw depth at 150 C (truncated coneplug mold at 20 mm/second speed).


of the heaters to the sheet or by adjusting theheating rates. This is helpful when coextrudedsheets are used.

• The force is measured using an accurate loadcell while the sample is losing heat, as is typicalof the actual thermoforming process.

• The ability to change forming speed can beuseful in studying the effect of increased linespeed.

• The unit allows changes in plug geometry andtype of plug material, simulating the effect ofplug materials.

• Once the part is formed, it is cooled undercontrolled conditions to determine the effect ofcooling on shrinkage, warpage, grain distortion,gloss variation, and so on. These observationscannot be made in any of the aforementionedmethods.

• The equipment is as easy to use as the melt flowindexer and it provides quantitative data undercontrolled conditions, which can be repeated.

Test ResultsExtruded sheets of nylon, HDPE, ABS, PP, PC,

PVC, PMMA, POM, HIPS, PETG, filled TPO, andHMS-TPO were obtained from suppliers. Sampleswere cut from various feedstocks andthermoformed using a 100 mm long, 50 mmdiameter, 30-degree truncated cone plug undervarious plug speeds and sheet temperatures.

Figure 2 shows the relationship between theforming force and depth of draw at 150°C forseveral polymers. The required force increases withincrease in melt strength. Polymers with true strainhardening show an increase in the force requiredwith increasing draw depth, as seen for POM inFigure 3. For crystalline polymers, an increase inforce at the deepest draws is due to the cooling ofthe sheet as it contacts the cold plug. The sagdistance can be estimated from the depth ofpenetration of the plug before the transducermeasures a non-zero force.

Figure 4 shows the effect of sheet temperatureon the force required to form various polymers toa draw depth of 100 mm at 20 mm/second usingthe truncated cone plug. As seen for most

Figure 4. Relationship between forming temperature and force(truncated cone plug at 20 mm/second speed).

Figure 3. Effect of cooling on force for Acetal (Cup mold, 20 mm/second).


Figure 5a. HMS-TPO, effect of temperature at 20 mm/second, cupshape plug.


amorphous materials such as ABS, HIPS, PMMA,PVC and PETG, the force decreases nearly linearlywith sheet temperature. For crystalline polymers,the force does not decrease linearly. For HDPE andPP, a step change in the force occurs around thepolymer melt temperature. For nylon and PC, theforce actually increases around their melttemperatures.2

Figure 6. Tensile yield stress vs. temperature.

Figure 5c. Effect of forming speed.

Figure 5b. Effect of temperature, filled TPO.

substantial loss in melt strength whereas the HMS-TPO shows very little change in the sametemperature range. The increase in stress at greaterdeformation indicates a strain-hardening effect.

2 Ed. Note: Commercially available PC is normally an amorphouspolymer with a glass transition temperature of around 150°C.

Figures 5a and 5b show the effect of temperatureon the forming characteristics of talc-filled TPO andHMS-TPO. The TPOs have similar tensile strengthsand moduli at room temperature. HMS-TPO doesnot show a loss in melt strength while the filledTPO does. Figure 5c shows the effect of test speedon the forming characteristics of these twopolyolefins. At high speeds, the filled TPO shows

Figure 6 shows the tensile strength v. temperaturefor these two TPOs, measured at a 50-mm/mincrosshead speed. The HMS-TPO has a much highertensile strength than that for the filled TPO.

ConclusionsThe current test methods reviewed above do not

encompass the wide range of variables found ineven the simplest of thermoforming processes. Theproposed novel device has demonstrated its use indetermining the thermoformability of manypolymer materials. Quality control, processengineering, raw material suppliers, and materialsdevelopment engineers can use this simple butprecise device for addressing thermoformingmaterial- and process-related issues. With further


effort, a built-in predictive modelcan be incorporated to allowefficient process set-ups. ■

References

1. J. L. Throne, Technologyof Thermoforming,Hanser/GardnerPublications, Cincinnati,1996.

2. D. Hylton, “Laboratorytechniques for predictingmaterialthermoformability,”ANTEC 1991.

3. K. E. McHugh and K.Ogale, “High meltstrength polypropylenefor melt phasethermoforming,” ANTEC1990.

4. N. McCauley, E. Harkin-Jones, and W. R. Murphy,“Thermoforming ofpolypropylene,” PlasticsEngineering, July 1996.

5. V. E. Malpass and C. H.White, SPE Journal, Nov.,1971, Vol. 27.

6. G. R. Ziegchner and P. D.Patel, “Comprehensiveevaluation of PP meltrheology,” 2nd WorldConference on ChemicalEngineering, Montreal,October 1981.

7. B. Hagemann and P.Eyerer, “Improvingindustry throughtechnical development.”

8. D. Hylton and C.Tameka, “Rheologicalstudies of commercialthermoformingmaterials,” ANTEC 1988.

9. A. Dharia, U. S. PatentApplication 10/920,127.



Heating Filled PlasticsINDUSTRY PRACTICE

BY JIM THRONE, SHERWOOD TECHNOLOGIES, INC., DUNEDIN, FL

We’ve all heard the argument that filled plasticsheat at different rates than unfilled plastics.

This Industry Practice article explores thisargument with simple examples. The theoreticalanalysis will appear in a subsequent TechnicalArticle in TFQ.

We need to make some simplifying assumptions.Consider our filler to be TiO2, either an opacifier ata relatively low loading of 10 wt% (Example A) ora filler at relatively high loading of 40 wt%(Example B). For simplicity, consider the particleshape to be spherical with a particle size of 10microns. Consider the plastic to be generic. We’llneed to make additional assumptions later.

Some simple arithmetic, first.

Volume Fraction: The filler volume fraction is givenin terms of weight fraction as:

Volfract = wtfract (densitypolymer/densityfiller)

The density of TiO2 = 4.36. The density of ourgeneric plastic is 1.0, say. The volume fractions ofour two loadings are:

Example A: Volfract = 0.10 (1/4.36) = 0.0235 or 2.35vol%

Example B: Volfract = 0.40 (1/4.36) = 0.0917 or9.17%

Plastic-filled Density: The density of a filled plasticis given as:

1/rfilled = wtfract/rfiller + (1-wtfract)/rplastic

Example A: rfilled = 1/[0.10/4.36 + 0.9/1] = 1.08Example B: rfilled = 1/[0.40/4.36 + 0.6/1] = 1.45

Specific Heat: The specific heat or heat capacity isa measure of the amount of heat required to heatthe plastic to its forming temperature. The greaterthe specific heat, the more energy is required.

SpHtfilled = Volfract x SpHtfiller + (1-Volfract) xSpHtplastic

The specific heat of TiO2 is 0.2. The specific heatof neat generic plastic is, say, 0.4.

Example A: SpHtfilled = 0.0235 x 0.2 + (1-0.0235) x0.4 = 0.394

Example B: SpHtfilled = 0.0917 x 0.2 + (1-0.0917) x0.4 = 0.382

Thermal Conductivity: The equation for thermalconductivity of a filled plastic is relatively complex.It is the Nielsen equation, used to determine, amongother things, the mechanical properties ofcomposite systems.

kfilled/kplastic = (1+ABVolfract)/(1-BQVolfract)B = (kfiller/kplastic-1)/(kfiller/kplastic+A)Q=1+[(1-Volfractmax)/Volfractmax

2)]vA=kappaE-1Volfractmax = 0.6 (random spheres)kappaE = 2.5 (spheres)

The most important aspect of this equation is theterm, Volfractmax. This is the maximum packing thatcan be achieved with the particular filler. For thiscase, we assume that we have uniformlydimensioned spheres. As a result, A = 1.5.

Example A: Q = 1 + [(1-0.6)/0.62]0.0235 = 1.026B=(40/0.4-1)/(40/0.4+1.5) = 0.975kfilled/kplastic = (1+1.5x0.975x0.0235)/(1-0.975x1.026x0.0235) = 1.059

Example B: Q = 1+1.11x0.0917 = 1.102B = 0.975kfilled/kplastic = (1+1.5*0.975*0.0917)/(1-0.975*1.102*0.0917) = 1.258

Now we can summarize the changes in thermalproperties because of the presence of TiO2 in theplastic.



1 This is not quite correct, because we are not properly taking intoaccount the volume occupied by the filler. But, considering all theother assumptions …

SummaryFiller conc Inc in dens Inc in sp ht Inc in thermal k Inc in heatWt % duty0 1 1 1 010 8% -1.25% 5.9% 6.4%40 45% -4.5% 25.8% 38.5%

As expected, increasing filler concentrationresults in increased filled polymer density. Thespecific heat does not substantially decrease.Therefore, the total amount of energy required toraise a specific volume of filled plastic to its formingtemperature (that is, its specific gravity times itsdensity or its heat duty) increases substantially withincreasing filler concentration. In the case of 40 wt%TiO2, the additional heat duty is 38.5%.

In short, the more rock there is, the more energyit takes to heat it.

Now we explore another facet of this question:Does the presence of filler change the way in whichthe plastic receives radiant energy? To answer thisquestion, we need to consider geometry. This time,we consider a cube of plastic, T units on a side.Assume for the moment that the filler is compressedinto a cube, t units on a side. What is the volumeoccupied by the filler?

A simple form of the equation is:

Afiller = (t/T)2 = (Volfract)2/3

Example A: Afiller = (0.0235)2/3 = 0.082 or 8.2% of thesurface is filler

Example B: Afiller = (0.0917) 2/3 = 0.203 or 20.3% ofthe surface is filler1

We now need to make some simplifyingassumptions about the volumetric distribution ofthe particles in the plastic matrix. Recall that ourparticle size is 10 microns. We assume that theparticles are uniformly distributed throughout thevolume. As a result, the first 10 microns of the filledplastic are composed of about 8% filler for the 10wt% dosage and about 20% for the 40 wt% dosage.For the rest of this journey, consider only the higherdosage case.

As we know from FTIR graphs, all plastics aresemi-transparent to incident far-infrared radiation.Consider the case where the average transmission

of radiant energy though the first 10 microns ofplastic is 50%. This means that 50% of the incidentenergy is absorbed by the first 10 microns of plasticand 50% is transmitted to the next 10 microns.Furthermore, assume that in the next 10 microns ofplastic, 50% of that energy is absorbed and 50% istransmitted to the third 10 microns of plastic. Andso on.

As we said, we are using the 40 wt% dosage case.Assume that the filler particles reside in 10 micronlayers throughout the plastic. As a result, 20% ofthe first 10 microns of plastic contain filler particles.As does the next 10 microns and the next 10microns, and so on. For this analysis, consider thatall the incoming radiation that impinges on the fillerparticles is totally absorbed, to be ultimatelyconducted into the plastic.

Now consider inbound radiation to the first 10microns of filled plastic. That portion that impingeson the filler is completely absorbed. That portionthat impinges on plastic is only 50% absorbed, aswe assumed above. This is written as:

1st Layer:Absorbed: inbound radiation x filler area +

absorbed portion x open area =

Transmission: filler block of all radiation x fillerarea + transmitted portion x openarea =

Absorbed: 100% of 20% + 50% of (100%-20%)= 60%

Transmitted: 0% of 20% + 50% of (100%-20%) =40%

Now for the second layer, only 50% of the originalradiation is available. And an additional 20% of thesurface area is blocked by filler particles. So this iswritten as:

2nd Layer:Absorbed: 50% of 20% + 50% of 50% of (80% -

20%) = 25%



Transmitted: 0% of 20% + 50%of 50% of (80% -20%) = 15%

On to the third layer. Only 50%of the 50% of the previousradiation is available forabsorption and transmission.And an additional 20% of thatsurface area is blocked. So wewrite:

Total Layer-by-Layer AbsorptionFiller 1st 2nd 3rd 4th 5th 6th 7th

Conc0 50% 75% 87% 94% 97% 98% 99%40 60% 85% 95% 99% 100%


surfaces heating at a more rapidrate than those of unfilledpolymers. And normally we do.However, filled polymers havehigher thermal conductivitiesthan unfilled polymers. Thismeans that for filled polymers,the energy near the surface isconducted to the interior at afaster rate than that for unfilledpolymers. This is a veryimportant compensating factor.On balance, a polymer heats atabout the same rate whether neator filled. ■

3rd Layer:Absorbed: 50% of 50% of 20%

+ 50% of 50% of50% of (60% - 20%)= 0.10

Transmitted: 0% of 20% + 50%of 50% of 50% of(60% - 20%) = 0.05

And so on. Consider atabulation of these absorptiondata, compared with energyuptake of the unfilled plastic:

It is apparent that the fillerblocks radiation transmissioninto the polymer. Therefore, allthings being equal, the sheetsurface should heat at a rate thatincreases with increasing fillerconcentration. And, becauseinfrared thermometers measuresheet surface temperature, filledpolymers appear to heat fasterthan unfilled polymers.

But wait. As we saw earlier,the thermal conductivity of thefilled plastic increases withincreasing filler dosage. Thismeans that even though thesurface of a filled plastic receivesmore energy than that of anunfilled plastic, the energy isconducted into the interior of theplastic at a faster rate.

ConclusionThere are two general aspects

to energy input to filled plastics.The first is that the energyneeded to raise a filled polymerto its forming temperature

increases with increasing fillerconcentration. The primaryreason is that the plastic densityincreases with increasing fillerconcentration.

The second is that at the sameenergy input rate, filled polymersurfaces absorb more energythan unfilled polymer surfaces.If this were the only effect, wewould see filled polymer

We need your

continued

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recruitment!!


Distortion Graphics for Thermoformed Parts –Elastic Image, A Development of

Rose-Hulman Institute of Technology

UNIVERSITY NEWS

Who are we?We are graphics and plastics professionals backed

by a strong corps of engineers and softwarescientists. We have developed an automated digitalsolution for distorting graphics for pre-decoratingplastics. We are partnered with Rose-HulmanVentures (RHV), a technology incubator arm ofRose-Hulman Institute of Technology in TerreHaute, IN. Together we have developed proprietarysoftware and hardware to expand capabilities inthe manufacturing of decorated plastic products fora wide variety of applications. Our partnership withRHV allows us to accelerate our technicaldevelopment through R & D and engineeringinitiatives. As a result, EI has established thebenchmark for exceptional quality in pre-decoratedplastics.

What are we selling?We deliver the ability to advance manufacturing

capabilities for decorating formed plastic products.We provide the means for manufacturers toeliminate the risks and design limitations inherentin the outdated trial-and-error methods fordistorting graphics. EI provides speed-to-market inboth the development and production phases. Wedrive value at every touch-point in the cycle fromdesign concept to final delivery. Designers, toolmakers, plastics companies, graphics producers,and forming manufacturers are embracing the EItechnology. We enable clients by providing a uniqueplatform for increased creativity and designflexibility. We develop new products that deliverincreased value-added. Our technology offerspowerful differentiation opportunities for ourcustomer’s products and brands.

How was it developed?The current technology is a proprietary

integrated suite of hardware and softwarecomprised of machine vision-based data collectionand graphic distortion computation. It is the resultof the marriage of development between twogroups of software scientists and engineers. Eachgroup tackled part of the challenge. An RHV groupdeveloped the 3D scanning solution that quantifiesmaterial stretch while another developed thegraphics distortion package. These two platformtechnologies were brought together initially in 2003.In parallel with commercial rollout, EI hascontinued to improve both platforms and is nowin its fourth phase of development. EI and RHVcontinue to commit resources against the ongoingdevelopment and evolution of the technology.


How does it work?Unlike attempts to develop distortion solutions

through predictive means, the EI solution is basedon capturing the specific surface dynamics of a



plastic part during the formingprocess. At the core of it, weproduce distortions based onscientific measurement. Toachieve the desired end result interms of graphic quality andregistration to the form, the EItechnology provides a graphicsfile precision-engineered for pre-decoration – regardless of thenature of the thermoform toolingdesign, substrate or print processassociated with that particularpart.

The technology is easilyintegrated into graphics andforming manufacturingenvironments through a simplequalification process to ensurerepeatability. Basically, it’s plug-n-play. Numerous thermo-forming manufacturers withoutany previous experience withdecorated sheet have easilyapplied the EI technology. EItechnology seamlessly integrateswith current and leading-edge3D design, CAD and graphictechnologies.

What is the differencefrom status quo?

The previous state-of-the-artfor distorting graphics was justthat – an art form. It was acombination of trial-and-errormethods and know-how basedon experience. Designers andmanufacturers worked withinhighly restricted designparameters and with a strongelement of risk andunpredictability associated withquality, delivery time, and cost.

EI introduces an automateddigital technology, whichrenders previous design limita-tions a thing of the past.Leveraging EI’s technologyopens graphics and toolingdesign to a new world ofopportunities. Manufacturerscan stretch the limits for productdesign with delivery certainty.Three-dimensional parts withworld-class graphics are the newbenchmark for decoratedplastics.


P ERFORM A NC E. INNOVAT ION. DEPENDABIL ITY.

Proven Partnership.Worldwide Benefits.For the best in trim-in-place and high volume thermo-

forming equipment, parts and service, talk to the

global experts at Lyle and Gabler. Call 989-435-7717

for details, or visit lyleindustries.com.

4144 W. Lyle Road ■ Beaverton, MI 48612www.gabler-maschinenbau.de

Who can benefit fromyour technology?

Current clients includethermoformers, printers, adver-tising agencies, merchandisers,gaming companies, packagingmanufacturers, outdoor adver-tisers, promotional companiesand vending manufacturers.Any groups within the valuechain of all segments of thedecorated plastics industrybenefit from application of thetechnology.

Where do you seeElastic Image in thefuture?

Elastic Image proprietarytechnology is rapidly emergingas the world standard platformfor distorting graphics. ■

Please contact

Elastic Image, Inc.,

100 S. Campus Drive,

P.O. Box 3799,

Terre Haute, IN 47803,

1-812-244-4000, or visit

our website:

www.elastic-image.com,

for more information.


History of Thermoforming – Part IIIINDUSTRY PRACTICE

BY STANLEY R. ROSEN, PLASTIMACH CORPORATION, LAS VEGAS, NEVADA

Ed. Note: The philosopher Santayana said “Those who cannotremember the past are destined to repeat it.” Stan Rosen isundertaking a prodigious project – identifying the pioneerswho laid the foundations of the industry we know so well.Although shaping of sheet extends back to pre-history – oil-heated and shaped tortoise shell and steam-heated and shapedwood. In TFQ 24:3, Stan started his history withdevelopments in the 1930s. We hope you are enjoying thetrip!

Mechanically FormingThermoplastics Parts Prior to theThermoforming Age – Part One

Commercial thermoforming machinery and formingtechnology developed quickly in the U.S. during theearly 1950s. Prior to that date, thermoplastics were mostoften formed mechanically using various methods byfirms specializing in providing formed plastic productsto their customers. These mechanical formingtechniques were slow, labor intensive, and did notalways provide reproducible results. Several visionarycompanies during this era invested in the design ofthermoforming equipment to suit their own needs.However these machines were not sold on the openmarket. Borkland Laboratories licensed vacuumforming equipment in the late 1940s. Plax Corp. builtand used automated thermoforming machines in the1930s and Plaxall Corp. apparently built inlinethermoformers for their own production in the early1950s. A majority of the plastics fabricators continuedto use mechanical forming techniques until commercialvacuum forming equipment was first publiclydemonstrated at the National Plastics Exhibition inMarch 1952. Within one year, thermoforming activityexpanded explosively as equipment and technicalinformation became available to industry.

Mechanical forming of thermoplastic sheet borrowedsome of the methods which were in use in the metalworking and paper-box making industries. A metaldeep drawing technique for fabricating a pot or panfrom metal blanks was modified to process celluloidinto seamless transparent packaging from individualplastic blanks. Paper box manufacturers employed die-cutting, creasing, bending and the cementing of box

corners for their products. Many of these paper boxprocedures were suitable for the production of plasticboxes and lids. Other forming processes modified fromthe glass blowing and metal forming industries wereadapted to accommodate the physical properties ofplastics materials.

Celluloid, a combination of cellulose nitrate, campholand other chemical additives, was the first commercialplastic sheet available in 1868. Equipment to fabricatethe sheet used a “blow form process” in which twoheated celluloid sheets were placed between femalemolds and when the press was closed the cavityperimeter edges were trimmed and heat sealed together.Steam pressure then entered between the sheets to forcethe pre-heated plastic into the cavities. (Fig. 1, Fig. 2).

Figure 1. Blow-form press.

Figure 2. Blow-form mold.(continued on next page)


Figure 3. Manual deep drawing machine. Patent by H. E.Helmstaeder-1937.

This process, which is similar to modern twin sheet-forming or blow molding, was used for production ofdouble-faced parts such as balls, baby rattles, etc,starting in the 1890s. The same process could form oneheated sheet into a female cavity producing shallowformed open-faced parts similar to a blister packagingcomponent.

The city of Leominster, Massachusetts became thehub of the celluloid era (1900-1920) manufacturingactivities and it pioneered in all types of plasticsfabrication, especially blow forming. The ancillarycomponents for manufacturing finished plasticscomponents such as molds, presses and dies weremanufactured here and sold worldwide. Thispioneering city of the plastics industry is the home ofthe National Plastics Center and Museum where earlyplastics processing equipment is on display.

Manual deep drawing of thermoplastic sheets isdescribed in a 1937 patent by William E. Helmstaedter,of the Celluloid Corp. (later Celanese Corp.) as follows(Fig. 3):

(continued from previous page) applies its weight to prevent the sheet from wrinklingduring forming, allows the plastic flange to slip betweenthe hold-down plate and the face of the hot die. Thisheated flange area provides the necessary additionalmaterial to form the finished part. Blanks thicker than.015 inch (.38 mm) require preheating in an oven andthen are manually transported quickly to the formingpress. Unlike the thermoforming process, where theheated sheet thins as it is being formed, deep drawing“steals” material from the flange as it slides betweenthe former and the die and produces a fairly uniformsidewall.

Trimming and heat sealing of the finished drawn partedge takes place when the punch strikes the top surfaceof the die, causing the formed part to be trimmed by aheat pinch-off action. The more traditional punch anddie design which is in more common usage in theindustry allows the punch to cut through the plasticand enter the die cavity. Helmstaedter stated in thepatent that a small temperature differential between aheated traditional punch and die could cause trimmingproblems. If the punch is cooler than the die, the toolclearance will increase and possibly cause a roughtrimmed edge. A punch which is hotter than the diecan reduce the clearance to zero causing a die smashup.These facts are recognized on modern thermoformersthat form and trim in the same station using a punchand die, since this type of tooling receives considerableheat from the hot web. The control system of thesenewer machines can shut down the equipment if theydetect an unsafe temperature differential between thetwo halves of the tool. ■

[To be continued]

ReferencesAutomatic Pressure Thermoforming, Plaxall Corp.

L.I.C. N.Y

Modern Plastics Magazine, July 1953.

Inline Roll Fed Thermoformer, C. B. Strauch Patent#2,229,613 filed 11-22-1938 assigned to Plax Corp.Hartford, Conn.

Vacuum Forming Machine, G. W. Borkland Patent#2,347,806 filed 7-8-1947 assigned to BorklandLaboratories, Marion, Ind.

Fig. 1 and Fig. 2 - Plastics History U.S.A., J. H. Dubois –1972, pgs. 45 and 347.

Fig. 3 - Manual Deep Drawing of Plastics Packaging,W. E. Helmstaedter, Patent #2,255,116 filed 1-21-1937assigned to Celluloid Corp., Newark, N. J.

A temperature-controlled “former assembly”consisting of a male cavity and a hardened cutoff punchis mounted to the top moving platen. The punch islocated on the back face of the male cavity. The oppositestationary platen contains a heated die whose interioredge is rounded slightly to assist plastic flow betweenthe die opening and onto the moving former. A heavyhold-down plate (much like a clamp frame), which


Draft AnglesBY JIM THRONE, SHERWOOD TECHNOLOGIES, INC., DUNEDIN, FL

THERMOFORMING101

1 These parts are sometimes called an-drogynous, meaning that they have bothfemale and male characteristics.2 Exacerbate: To aggravate.

Some time ago, we discussedshrinkage and warpage. At

that time, we pointed out thatplastic, like most other materials,increases in volume whenheated and decreases in volumewhen cooled. And we said thatto form the desired shape, thehot plastic is pushed against acool mold surface. It follows thatas the plastic cools, it shrinks.But the mold doesn’t change indimension. If the mold is maleor positive, or if even a portionof the mold is male or positive,the plastic will shrink onto themold surface. And if the mold isnot properly designed, we willhave a devil of a time getting thepart off it. Thus we face thesubject of draft angles.

Draft Angles – DefinedThe best definition of a draft

angle is the angle the mold wallmakes with the vertical. If themold wall is vertical, the draftangle is zero. Recall that mostthermoforming molds aresingle-surfaced. That is, the sheetis pulled into or over a singlemold surface. For draw-downinto a female or negative mold,the sheet is constrained on itsouter surface by the mold. As aresult, when the sheet cools, ittends to shrink away from themold surface. As a result, it is

entirely feasible to thermoforminto a female mold having zerodraft angles. Most part designersprefer a slight draft angle, say 0°

to 2°, “just in case.” The averageis generally 1/2° to 1°.

On the other hand, when thesheet is drawn over a male orpositive mold, it is constrainedon its inner surface by the mold.As a result, when the sheet cools,it tends to shrink onto the moldsurface. To release the part fromthe mold, it is necessary toprovide a draft angle on thevertical mold surfaces. Theamount of draft dependsstrongly on the volumetricchange in the polymer. If thepolymer is amorphous – PS,PVC, PC – the draft angle maybe no more than 2° to 3°. If thepolymer is crystalline – PE, PE –the draft angle may be in excessof 5°. The average is generally 4°

but the designer must be alert toeffects of temperature variationand recrystallization rates.

A textured surface requires anincrease in draft angle. It isrecommended that the draftangle be increased at least 1° forevery 0.2 mils [0.0002 in or 5

microns] in texture depth. Keepin mind that increasing appliedpressure, sheet temperature, andmold temperature will result ingreater penetration of the sheetinto the texture.

What About PartsWith Male and FemaleComponents?

Multiple-compartment traysand pallets1 can pose seriesdrafting issues. Consider afemale cavity bordered by twomale segments. The sheet willattempt to shrink away from thefemale mold surface but onto themale segments. Excessive drafton the male segments may allowthe sheet to release from thefemale mold surface before thesheet has replicated the moldsurface. On the other hand,inadequate draft on the malesegments may allow the sheet tosatisfactorily form the femalemold surface, but the sheet may“lock” onto the male segments.The problem is exacerbated2

when molding compartmenttrays where the male portions are



BOOK REVIEWinterrupted. Essentially interruptedwalls in the molded part. Inaddition to the shrinkage issues,interrupted male segments mayalso be sources of internalwebbing3.

How Serious is theDraft Problem?

The draft angle can lead toserious dimensional changes in theformed part. Consider a simpleexample, a 10-inch male mold. Thevertical wall is 1 inch wide at thetop. Consider a draft angle of 5°.The width at the bottom of thevertical wall is determined asfollows:

The increased width on one sideis 10 x tan 5° = 0.875 in. The totalwidth at the bottom is then 1 + 2 x0.875 = 2.75 in.

This is a substantial dimensionalchange in the thickness of thevertical wall.

When is the DraftAngle Not a DraftAngle at All?

When it is used for somethingelse. The classic example is thedrink cup. The sidewalls aretapered as much as 20° for stackingpurposes, not shrinkage. In multi-compartment parts, care must betaken in the design toaccommodate both the draft anglerequired for shrinkage and thenecessary stacking taper. Stackinglugs, stand-offs, or rings are oftendesigned into complex parts,simply because it is not alwayspossible to predict the exact localshrinkage. ■

Keywords: draft angle, taper,shrinkage


3 Webbing will be discussed in a later les-son.

M. W. Hill, Measuring to Manage:Using Measurable Data to GetMaximum Employee Perform-ance, paperback, 2003, 88 pages,$16.95 + $3.00 S+H. Order directlyfrom Michael Hill, P. O. Box 20522,Indianapolis, IN 46220-9998.

I am always skeptical of theschemes proposed in the help

guides for managers, dozens ofwhich are published each year.Most of these repeat the same orsimilar mantra regarding manager-employee goal setting and reviewprocedures. I am always remindedof the Dilbert cartoon where hispointy-haired boss (aka PHB)presents Dilbert with a long list ofprojects. When Dilbert asks himwhich are A priority and which areB and C priority, PHB tells him thatthis is the A list and that he has yetto make up the B and C list.

Michael Hill is VP of anindustrial distribution center withfive branch locations and over 100employees. He has been a memberof SPE for more than 20 years andis past president of theInternational Association of PlasticsDistributors. He has an MBA fromSt. Bonaventure University. Mr. Hillhas written a modest book with avery modest goal and haspublished it at a very modest price.According to the introduction, it“deals with teaching managers toachieve their goals by usingmeasurable criteria to evaluateemployee performance.” The bookhas 11 chapters – Problems inToday’s Climate, What a CompanyShould Do, Setting Your EvaluationGoals, Measuring, “Your”Evaluation, Pre-Review Tips,Examples, The Actual Review,Future Encouragement, When All

Else Fails, and Final Word onMeasuring.

In addition to being veryreadable, the book contains manyquotable statements. For example:

“A mediocre product … withgood people will easily outperforma great product marketed by a weakorganization.”

“A goal, by definition, needs tobe measurable …”

“Don’t risk losing yourinvestment in your employees dueto poor management.”

“Reviews based on measurablecriteria hold no surprises for theemployee …”

“Always be on the lookout formeasurable criteria …”

“… every company wants …employees [to accept] responsi-bility for their actions, and in fact[to review] themselves.”

Hill argues that performancereview and salary review should beseparate entities. And thatperformance review has threecomponents – managementpreparation, human resource input,and employee preparation. Hismantra can probably besummarized by this:

“Without a yardstick there is nomeasurement. And withoutmeasurement, there is no control.”Toward this, he outlines a five-stepprogram for achieving qualityemployee reviews.

Hill’s book is a fast read, with histhesis outlined only after he has“set the table” by discussing thefailure aspects of other types ofreview. The reader should be fullyaware that Hill’s proposedprogram needs to be designed byeach manager to meet the needs ofhis/her employee team. And thatthis design is the sole responsibilityof the manager. Hill’s thesis istechnically viable so long as themanager-employee structureremains stable over an extendedperiod of time.


. Outstanding for ABS, PC/ABS, PVC and HIPS

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www.solarkote.com Phone: 215.419.7982

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Capstock solutions for thermoformed sheet.

Altuglas® and Solarkote® are registered trademarksbelonging to Arkema.© 2005 Arkema Inc. All rights reserved.


Auctions • Appraisals • Liquidations New and Used Machinery Sales

Thermoforming • Injection Molding • Extrusion Blow Molding • Rotational Molding

Supplying the World with Plastic Processing EquipmentSupplying the World with Plastic Processing Equipment

Why buy with Stopol:If it is out there, we will find it. With our database of more than 27,000 companies, we will locate the

equipment you need.

Our expertise and knowledge will provide you with the best machines to meet your needs.

Our vast inventory provides you with a variety of choices and alternatives.

Photos and video footage are available.

Why sell with Stopol:

Actively market your equipment to more than 27,000 companies, utilizing phone, fax, email and

advertising campaigns to get your equipment in front of qualified buyers.

We include your equipment on our web site which produces more than 125,000 hits per month.

We team with the most recognized and trusted publications in the plastics industry -- Plastics

News, Modern Plastics, Plastics Hotline and Thermoforming Quarterly -- to market your equipment.

Global presence with offices in London and Shanghai.

Whether its remarketed plastics processing equipment, a plant auction, inventory liquidation, or the sale and acquisition of a business, product line, or manufacturing license –

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STOPOL NEWS Lyle Industries, Inc. has announced the appointment of Stopol, Inc. as exclusive representatives to market the Lyle RFT Custom thermoformer and related equipment in North America. The RFT Custom offers complete form-trim stack capabilities in an economical, rugged package. Standard mold size is 32 x 36 inches. An available quick-change tooling package helps make the RFT Custom a versatile, efficient choice for a variety of applications, and the heavy duty construction helps ensure durability and precise thermoforming performance.

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Phone: +86 21 6122 1302 Fax: +86 21 6122 2418 [email protected]

But this reviewer sees threeaspects of the proposal that remainlargely unaddressed. The first dealswith quixotic managers whoconsider reorganization as part oftheir obligation. Reorganizingemployees and employeeresponsibilities on a frequent basisdoes not lead to development ofdedicated people. The second dealswith the reality of today’s market.Very often, companies haveextremely skilled and dedicatedpeople who are working in areasbeing marginalized by shiftingmarkets. Acquisitions, mergers,and buyouts enable to company torapidly shift to the newly emergingmarkets, but unfortunately oftenforce the company to surplus theirbest workers who simply cannot beretrained fast enough. And thethird deals with rating managers.Too often, employees have no wayof measuring the effectiveness oftheir manager to manage them.Managers may be oblivious tomannerisms or actions that, while“politically correct,” irritate andannoy their people. This isparticularly true of managers whomanage by the book rather thanlead by example.

So, is this a book that everymanager should read? Sure. It hasfar more substance and is mucheasier to digest than do some of theweekly columns in the Wall StreetJournal. But it is this reader’s beliefthat good managers shouldpurchase copies for each of theiremployees. The employee wouldthen be aware of the reasons behindthe five-step criteria being used torate him or her. After all, even Hillsays that “[w]hen companyinformation and company goals areshared and agreed upon, everyonewins.”

I rate this modest effort a strongfour-and-a-half books out of five.

~ Jim Throne, Tech Editor


2006 THERMOFORMING CONFERENCE SEPTEMBER 17-20

NASHVILLE CONVENTION CENTER & RENAISSANCE HOTEL NASHVILLE, TENNESSEE, USA

NAME: SPE MEMBER #:COMPANY: TITLE:

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WORKSHOPS (included with full registration) ( ) One for Sunday, September 17

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( ) One for Wednesday, September 20 Geiss Workshop (attendance limited to 100) Extrusion Workshop (attendance limited to 100) Presented by the SPE Extrusion Division

ONE-DAY FULL-CONFERENCE REGISTRATION (Sessions, Exhibits & Meals) $Early Registration SPE Member Rate - $200 Nonmember Rate - $330 After August 15/Onsite SPE Member Rate - $250 Nonmember Rate - $380

( ) One: Monday, September 18 Tuesday, September 19

EXHIBIT-HALL ONLY (Does not Include Meals, Breaks, Workshops or Technical Sessions) $Early Registration $50 per day / $75 both daysAfter August 15/Onsite $75 per day / $150 both days

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DIVISION

®


January is National MentoringMonth. There are many ways to

become involved with mentoring.One of the best is for companies tooffer internships to universitystudents studying for a career inplastics. Student internships mighthelp slow the long-term erosion ofthe manufacturing sector in theU.S., and there are many otherbenefits as well. What are thosebenefits? Ask Joe Peters, presidentof Universal Plastics in Holyoke,Mass. Ask Lucas Stallbaumer, astudent of plastics engineeringtechnology at Pittsburg StateUniversity in Pittsburg, Kansas.Here is their story.

Lucas Stallbaumer wanted toknow what he was getting himselfinto. At the end of his junior yearat Pittsburg State – pursuing abachelor ’s degree in plasticsengineering technology, with anemphasis in manufacturing – Lucasdecided to apply for a summerinternship. He desired “hands-on”working experience at a plasticscompany. Lucas also wanted achange of scenery: he had neverseen the ocean.

When Bill McConnell ofMcConnell Co., Inc., a member ofthe Board of Directors of SPE’sThermoforming Division and amember of Pittsburg StateUniversity’s Plastics AdvisoryCouncil, spoke to Lucas and fellowstudents enrolled in plasticstechnology classes, he provided alist of companies specializing inthermoforming that mightwelcome student interns. Lucasemailed all the companies on the

JANUARY IS NATIONAL MENTORING MONTH

What Are You Getting Yourself Into?ALICE BLANCO, SENIOR ASSOCIATE EDITOR, PLASTICS ENGINEERING MAGAZINE

list. He received responses – andoffers of internships – from two.

Lucas accepted the offer from JoePeters, president of UniversalPlastics in Holyoke, Mass., and hissummer-of-2005 internship began.On May 29, Lucas boardedSouthwest Airlines flight 132 K inKansas City, bound for Massa-chusetts. His mother was not asexcited about the trip as Lucas was.“My mom cried most of the way tothe airport,” he recalls. Rich andSue Peters (Joe’s brother and sister-in-law) shared their home inWestfield, Mass., with Lucas for thesummer. “I was welcomed andtreated as part of the family. For thisI am really thankful. It sure beatstaying in a dorm room,” saysLucas.

At Universal Plastics, Lucassettled in with his own desk andcomputer in the engineeringdepartment. Joe Peters wanted tomake sure that during the summer,Lucas’s work duties took him intoevery area of the shop – fromactually forming some parts toworking with tooling andsecondary operations. “I wantedhim to work with engineers, super-visors, and line employees,” Joesays. Lucas was involved in newand ongoing projects, and wasgiven a number of tasks, such ashelping to design a package, testingdesigns, and sourcing materialsand hardware for products thecompany manufactures.

His number-one job, reportsLucas, was assisting the company’sforming department by creatingcomputer spreadsheets that listeddata pertaining to the forming of

parts. The easy accessibility ofLucas’s electronic data sheetseliminated the need to shufflethrough piles of unorganizedpapers in search of a particulardocument (if indeed one was to befound) and greatly facilitated thesearch for information on aparticular part to be set up on amachine for production. Workingon the spreadsheets familiarizedLucas with the materials beingused, heating and cooling times,mold temperatures, forming pres-sures, and the PLCs (program-mable logic controllers) of variousmachines, he says. Joe reports thatLucas’s computer skills were highlyvaluable to the company: “He wasin demand when others found outthat he was great at designingforms.”

The most important thing Lucaslearned during his internship: inthe real world of producing parts,“things can become very frus-trating very fast if things do not goright, but you have to keep yourcool and get the job accomplished.”In helping with the thermoformingof 5-inch polyurethane cones, forexample, Lucas observed thatfrequent and capricious changes inprocessing parameters (e.g.,humidity, temperature, materialthickness, and air pressure) makeit challenging to produce consistentweb-free parts that are neither toothin nor too short, and to producethem on time. Lucas was alsoabsorbed in figuring out theprocess needed to apply largeprinted vinyl stickers to streetsigns. The stickers had to beperfectly centered and straight,


with no distortions in the print atall and no air bubbles or waterintrusion, which would void themanufacturer’s warranty. It was ahurry-up job to meet thecustomer’s demand for a shortturnaround time.

In an academic setting, one mightencounter a difficult problem,postpone a solution, and return todeal with it another day. In thebusiness world, walking away eventemporarily from an unsolvedproblem is not an option. An idlemachine shrinks a company’sprofits, and poor-quality parts orparts delivered late make fordisgruntled customers, who mighttake future business elsewhere.Lucas points out: “So yourcompany loses money and youcould lose your job.”

Throughout his internship atUniversal Plastics, Lucas says, helearned lessons he did not expectto. “I learned the key aspects ofbusiness – from engineering tosales, research, forming,machining, quality control, andshipping. I learned a lot from all thesteps involved in the entirebusiness.” Lucas also establishedbusiness relationships andfriendships with his coworkers thathe thinks will last a lifetime. “Iwould suggest more students takepart in an internship before they getinto the workforce, to see what theyare actually getting themselvesinto,” he says.

Lucas thinks more companiesshould approach local colleges toseek interns, to train students inhopes that upon graduation theywill join the staff as permanentemployees. “That way,” he says,companies “will not have to spendas much time or moneyfamiliarizing them with proce-dures, processes, machines, people,and other things that make acompany run.”

Joe Peters says, “Unfortunately,kids today are not being exposedto manufacturing and engineering

as a career path. They are not awareof the technology involved and themany rewards of creating andmanufacturing products. Givingthem an opportunity to spend sometime [in the work environment] isinvaluable in helping them maketheir career decisions.” Further-more, he adds, in the U.S. the realityis that we have to do as much aswe can to promote manufacturing,which is quickly diminishing as aneconomic force in our country.Helping students acquire first-handexperience is an extremely valuabletool.

By the way, Lucas did get to seethe ocean – at the Peters family’svacation home in Maine. Hewalked the beach, dined on lobster,and sailed on the Atlantic. Hehelped hoist the mast and sail theboat, and even accompanied thePeters’ son Andrew on a flyinglesson. Andrew’s aerial stunts –spinning in circles, ascendingstraight up, and killing andrecovering the engine – made hima bit dizzy, Lucas admits, but thescenery below was beautiful. ■

Joe Peters, president of UniversalPlastics, invited Lucas Stallbaumer, astudent of plastics engineeringtechnology at Pittsburg StateUniversity, Kansas, to spend thesummer as an intern at his companyin Holyoke, Massachusetts.

In Memory

of

R. Lewis

Blanchard

Past Thermoformer

of the Year

It is with sadness that we an-nounce the passing of R. Lewis

(Lew) Blanchard. Lew passed awayon December 12th, 2005 at hishome in Lafayette, Indiana.

He began his career in thermo-forming at Dow Chemical in Mid-land, where he worked on allphases of heat fabrication of ther-moplastic materials and PVC for-mulations. As a representative ofDow, he helped start SweetheartPlastics’ first thermoforming plant.

While at Dawbarn Brothers inWaynesboro, VA, he developed thefirst process for polypropyleneheavy denier fibers and strappingand worked on polyethylene fi-bers. At Kent Plastic Corp. inEvansville, his work included de-veloping sheet extrusion andthermoforming of refrigerator doorliners as well as thermoformed endcaps for fiber cans, cottage cheesecontainers, flower pots and clo-sures for recloseable cans.

He was inducted in the PlasticsHall of Fame and was also the 1994Thermoformer of the Year. Lewwas very active in the Society ofPlastics Engineers, serving asChairman of the ThermoformingDivision and a member of theirBoard of Directors.

Lew is survived by his wife Patand three daughters.

The Society of Plastics Engineersand the Thermoforming Divisionmourns the death of a dear friendand loyal member of this group. Hewill be missed. ■


[The Thermoforming Quarterly was established at thebeginning of 1998 and evolved from Thermoforming,the newsletter of the Thermoforming Division of SPE.Volume 17 Number 1 was the first issue of TFQ. Volume19 Number 1 carried the Index from 17:1 through 18:4.Volume 21 Number 1 carried the Index from 19:1through 20:4. Volume 23 Number 1 carried the Indexfrom 21:1 through 22:4. This issue continues the Indexfrom 23:1 through 24:4.]

Index of Technical Articles by Issue

TFQ 23:1, 2004Industry Spotlight: Shepherd Thermoforming and Packaging,Inc., The Birth of a Custom Thermoforming Operation, pp. 5-8.The Efficiencies of Infrared Heating Technologies Used in theThermoforming Industry, N. Bedard and S. Marchand, pp. 10-15.The Role of Preheaters in Thin-Gauge Forming, J.L. Throne, pg.16.TF 101 – Recrystallization-What Does That Mean?, pp. 18-19.Book Review – eBay on the Internet, pp. 20-21.

TFQ 23:2, 2004Optimization of Acrylic-Capped ABS Coextruded Systems ForSheet Applications, H. R. Banyay and T. Pope, pp. 10-15.Designing Knife-Like Dies for On-Line Continuous WebThermoforming, S. R. Rosen, pp. 16-19.A Thermoforming Transatlantic Divide?, C. Carlin, pp. 20-21.TF 101: Alphabet Soup?, pp. 22-24.Book Review: C. P. MacDermott and A. V. Shenoy, SelectingThermoplastics for Engineering Applications, pp. 26-27.

TFQ 23:3, 2004Optimization of Processing Conditions in Thermoforming, C.M.Bordonaro, T. L. Virkler, P. A. Galante, B. Pineo, and C. E. Scott,pp. 8-13.4th European Thermoforming Conference, March 25-27, 2004 –Viareggio, Italy, C. Carlin, pp. 14-15.TF 101: ABCs of Alphabet Soup, pp. 18-19.Book Review: W. E. Brown, Plastics in Food Packaging:Properties, Design, and Fabrication, pp. 22-23.

TFQ 23:4, 2004Interlayer Adhesion of Co-Extruded Sheets Before & After BiaxialStretching, H. Zhou, pp. 14-19.Getting 411 on U. S. Patents, J. K. Grogan, Esq., pp. 20-21.Understanding & Using Appraisals: Five Ways They Can Be Usedto Maximize Your Assets, D. Kruschke, pp. 22-23.TF 101: The XYZs of Alphabet Soup, pp. 24-25.RTP Company Opens New Sheet Extrusion Division, Anon., pg.27.Book Review: G. L. Beall and J. L. Throne, Hollow Plastic Parts:Design and Manufacture, pp. 28-30.

TFQ 24:1, 2005Spotlight on Industry: Productive Plastics, Lean Manufacturingat Productive Plastics: A Customer-Driven Approach, G. L. Boseand J. Zerillo, pp. 8-9.

THERMOFORMING QUARTERLY INDEX

Neuronal Networks Application for Characterization of SoftenedPolymers, F. Erchiqui and A.N. Kandil, pp. 10-15.University Highlight: Penn College, Industry Support HelpsCollege Promote Plastics Industry Careers, pg. 16.Energy Units in Thermoforming, J.L. Throne, pg. 17.Thermoforming: Growth and Evolution – Part I, J. L. Throne andP. J. Mooney, pp. 18-20.TF 101: Why is Part Design Important?, pp. 22-23.Book Review: Penny Sparke, Ed., The Plastics Age: From Bakeliteto Beanbags and Beyond, pg. 24.

TFQ 24:2, 2005Automotive Plastic Fuel Tank Systems, K. W. Albaugh, pp. 11-14.Design Features of a Multi-Cavity Mold Used for High-CyclicThermoforming, S. R. Rosen, pp. 15-18.Thermoforming: Growth and Evolution – Part II, J. L. Throneand P. J. Mooney, pp. 19-22.Irwin Research and Wonderpack’s Joint Venture, Anon., pg. 23.TF 101: Comparing Concept to Reality, pp. 24-25.Book Review: D. C. Hylton, Understanding Plastics Testing, pg.27.

TFQ 24:3, 2005Enhanced TPO Thermoforming Using High Melt StrengthPolyolefin Elastomers, K. L. Walton, M. K. Laughner, L. J. Effler,and E. S. Gisler, pp. 10-14.Collaborative and Methodical Product Development ReducesTime From Concept to Production, E. Hausserman, pg. 15.Proper Colleting and Collet Maintenance in CNC Routing ofPlastic, Van Niser, pp. 16-18.History of Thermoforming – Part I, S. R. Rosen, pp. 19-21.TF 101: Understanding How a Sheet Stretches, pp. 22-23.Book Review: G. L. Beall, The Evolution of Plastics in America(As Seen Through the National Plastics Expositions), pp. 24-25.

TF 24:4, 2005Investigation of Surface Properties of Pre-Stretching Plugs, D.Liebing, N. Tessier, T. Bush, and P. Eyerer, pp. 18-22.New CO2 Laser Cutting Technology, D. Cicchini, pp. 23-24.History of Thermoforming – Part II, S. R. Rosen, pp. 25-27.Design of Experiments – An Overview, D. Schoff, pp. 28-31.University Highlight:University of Wisconsin-Platteville, UW-PPlastics Processing Technology Center Receives Gift ofThermoforming Machine From MAAC and Division, pg. 31.TF 101: The Ubiquitous Draw Ratio, pg. 32.Book Review: J. L. White and D. D. Choi, Polyolefins: Processing,Structure Development and Properties, pp. 34-35.

Index of Technical and Industry PracticeArticles by Author

K. W. Albaugh, Automotive Plastic Fuel Tank Systems, TFQ 24:2,pp. 11-14.H. R. Banyay and T. Pope, Optimization of Acrylic-Capped ABSCoextruded Systems For Sheet Applications, TFQ 23:2, pp. 10-15.N. Bedard and S. Marchand, The Efficiencies of Infrared HeatingTechnologies Used in the Thermoforming Industry, TFQ 23:1,pp. 10-15.


Van Niser, Proper Colleting and ColletMaintenance in CNC Routing of Plastic,TFQ 24:3, pp. 16-18.T. L. Virkler, see C. M. Bordonaro.K. L. Walton, M. K. Laughner, L. J. Effler,and E. S. Gisler, Enhanced TPOThermoforming Using High Melt StrengthPolyolefin Elastomers, TFQ 24:3, pp. 10-14.H. Zhou, Interlayer Adhesion of Co-Extruded Sheets Before & After BiaxialStretching, TFQ 23:4, pp. 14-19.

Index of Continuing SeriesTitles

Industry SpotlightShepherd Thermoforming andPackaging, Inc., The Birth of a CustomThermoforming Operation, TFQ 23:1, pp.5-8.Productive Plastics, Lean Manufacturingat Productive Plastics: A Customer-Driven Approach, G. L. Bose and J.Zerillo, TFQ 24:1, pp. 8-9.

University SpotlightPenn College, Industry Support HelpsCollege Promote Plastics IndustryCareers, TFQ 24:1, pg. 16.University of Wisconsin-Platteville, UW-P Plastics Processing Technology CenterReceives Gift of Thermoforming MachineFrom MAAC and Division, TFQ 24:4, pg.31.

Thermoforming 101Recrystallization - What Does ThatMean?, TFQ 23:1, pp. 18-19.Alphabet Soup?, TFQ 23:2, pp. 22-24.ABCs of Alphabet Soup, TFQ 23:3, pp.18-19.


C.M. Bordonaro, T.L. Virkler, P.A.Galante, B. Pineo, and C.E. Scott,Optimization of Processing Conditions inThermoforming, TFQ 23:3, pp. 8-13.T. Bush, see D. Liebing.C. Carlin, A ThermoformingTransatlantic Divide?, TFQ 23:2, pp. 20-21.C. Carlin, 4th European ThermoformingConference, March 25-27, 2004 –Viareggio, Italy, TFQ 23:3, pp. 14-15.D. Cicchini, New CO2 Laser CuttingTechnology, TFQ 24:4, pp. 23-24.L. J. Effler, see K.L. Walton.F. Erchiqui and A. N. Kandil, NeuronalNetworks Application forCharacterization of Softened Polymers,TFQ 24:1, pp. 10-15.P. Eyerer, see D. Liebing.P. A. Galante, see C. M. Bordonaro.E. S. Gisler, see K. L. Walton.J. K. Grogan, Esq., Getting 411 on U.S.Patents, TFQ 23:4, pp. 20-21.E. Hausserman, Collaborative andMethodical Product DevelopmentReduces Time From Concept toProduction, TFQ 24:3, pg. 15.A. N. Kandil, see F. Erchiqui.D. Kruschke, Understanding & UsingAppraisals: Five Ways They Can Be Usedto Maximize Your Assets, TFQ 23:4, pp.22-23.M. K. Laughner, see K. L. Walton.D. Liebing, N. Tessier, T. Bush, and P.Eyerer, Investigation of SurfaceProperties of Pre-Stretching Plugs, TFQ24:4, pp. 18-22.S. Marchand, see N. Bedard.P. J. Mooney, see J. L. Throne.B. Pineo, see C. M. Bordonaro.T. Pope, see H. R. Banyay.S. R. Rosen, Designing Knife-Like Dies forOn-Line Continuous WebThermoforming, TFQ 23:2, pp. 16-19.S. R. Rosen, Design Features of a Multi-Cavity Mold Used for High-CyclicThermoforming, TFQ 24:2, pp. 15-18.S. R. Rosen, History of Thermoforming –Part I, TFQ 24:3, pp. 19-21.S. R. Rosen, History of Thermoforming –Part II, TFQ 24:4, pp. 25-27.C. E. Scott, see C. M. Bordonaro.D. Schoff, Design of Experiments – AnOverview, TFQ 24:4, pp. 28-31.N. Tessier, see D. Liebing.J. L. Throne, The Role of Preheaters inThin-Gauge Forming, TFQ 23:1, pg. 16.J. L. Throne, Energy Units inThermoforming, TFQ 24:1, pg. 17.J.L. Throne and P.J. Mooney,Thermoforming: Growth and Evolution– Part I, TFQ 24:1, pp. 18-20.J. L. Throne and P. J. Mooney,Thermoforming: Growth and Evolution –Part II, TFQ 24:2, pp. 19-22.

The XYZs of Alphabet Soup, TFQ 23:4,pp. 24-25.Why is Part Design Important?, TFQ 24:1,pp. 22-23.Comparing Concept to Reality, TFQ 24:2,pp. 24-25.Understanding How a Sheet Stretches,TFQ 24:3, pp. 22-23.The Ubiquitous Draw Ratio, TFQ 24:4, pg.32.

Book Review

G. L. Beall and J. L. Throne, HollowPlastic Parts: Design and Manufacture,TFQ 23:4, pp. 28-30.G. L. Beall, The Evolution of Plastics inAmerica (As Seen Through the NationalPlastics Expositions), TFQ 24:3, pp. 24-25.W. E. Brown, Plastics in Food Packaging:Properties, Design, and Fabrication, TFQ23:3, pp. 22-23.D. D. Choi, see J. L. White.eBay on the Internet, TFQ 23:1, pp. 20-21.D. C. Hylton, Understanding PlasticsTesting, TFQ 24:2, pg. 27.C. P. MacDermott and A. V. Shenoy,Selecting Thermoplastics for EngineeringApplications, TFQ 23:2, pp. 26-27.A. V. Shenoy, see C. P. MacDermott.Penny Sparke, Ed., The Plastics Age:From Bakelite to Beanbags and Beyond,TFQ 24:1, pg. 24.J. L.Throne, see G. L. Beall.J. L. White and D. D. Choi, Polyolefins:Processing, Structure Development andProperties, TFQ 24:4, pp. 34-35. ■


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The ThermoformingDivision of SPE hasproduced a new six-

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The DVD discusses the 13matching equipment

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grant. The 20scholarships to collegestudents are discussed

and information isprovided as how to apply

for a scholarship. TheThermoforming Divisionof SPE has contributed

over $150,000 inequipment grants and

scholarships as ofthis date.

The DVD is free of chargeand available from SPEthrough Gail Bristol at203-740-5447 or Gwen

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From The EditorThermoforming Quarterlywelcomes letters from itsreaders. All letters are subjectto editing for clarity and spaceand must be signed. Send to:Mail Bag, ThermoformingQuarterly, P. O. Box 471,Lindale, Georgia 30147-1027,fax 706/295-4276 or e-mail to:[email protected].


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ThermoformingQUARTERLY


Forming

Thermoformers, have

you discovered a

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are willing to share

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Then the

Just send Jim Throne a fax at727-734-5081, outlining yourtip in less than a couplehundred words. You caninclude drawings, sketches,whatever. Thanks!

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Materials (choose all that apply)Composites PolyolefinsFilm PolystyreneGeneral Interest TPEsNylon ThermosetPET VinylsFoam/Thermoplastics No Interest

Process (choose all that apply)Blow Molding Injection MoldingCompression Mold MakingCompounding Product DesignEngineering Properties Rotational MoldingExtrusion ThermoformingFabrication General InterestFoam No Interest

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Innovative Tooling Materials for Thermoforming

HYTAC®-WFT Plug Assist Material

The First Syntactic to Meet FDA and European Compliance for Food Packaging

[email protected] www.cmtmaterials.com TEL (508) 226-3901 FAX (508) 226-3902

CMT MATERIALS, INC.

Roger Fox David A. J. Morgese

(630) 653-2200

www.foxmor.com

1305 Lincoln Avenue, Holland, MI 49423PH (800) 833-1305 / FX (800) 832-5536

www.allenx.com

ABS ABSFR PCABSHIPS HIPSFR GELOYCENTREX LURAN NORYL

SOLARKOTE

A Tradition of Excellence Since 1970


P R O D U C T S / I N C

p l a s t i c s. . . . . . . . .

RAY™

The Experts inThermoforming

1700 Chablis AvenueOntario, CA 91761

909/390-9906800/423-7859

FAX 909/390-9896

www.rayplastics.com

Brian RayVice President/

General Manager

CUSTOM CUT SHEET & ROLL FED MACHINERYOVEN, CONTROL & INDEX RETROFIT KITSPATENTED ADJUSTABLE CLAMP FRAMES

3031 GUERNSEY ROAD, BEAVERTON, MIPH: 989-435-9071 FAX: 989-435-3940

Email: [email protected]



Brian RayPresident

[email protected]

Doug Benton

Standex Engraving Group5901 Lewis Rd.

Sandston, VA 23150

Ph: 804/236-3065Fax: 804/226-3462

• Design analysis for better heat transfer.• Extrusion know-how from A to Z.• Problem-solving, troubleshooting expertise.• Total in-house production. • Over 30 years of roll experience.• Repair and refinishing services.

Call an Xaloy roll specialist today!

Heat transfer solutions you can count on

Chill Rolls Optimizedfor You

800-897-2830 • 724-656-5600 • E-mail [email protected]. • www.xaloy.com

ARES …CNCMACHININGCENTERSFORMACHINING PLASTIC AND COMPOSITEMATERIALS

CMS North America, Inc.Grand Rapids, MI800.225.5267 Fax: 616.698.9730

®

[email protected]


SOLVE COST & PERFORMANCE PROBLEMS� Over 40 specialized grades

satisfy highest performanceto lowest cost applications:– Aircraft– Mass transit– Building products– Weatherable– Conductive/ESD– Multi-purpose

� 10 Surface Textures

� Thickness from 0.028”to0.500”

� Certified Fire Ratings:– UL Std. 94 V-0 and 5V– UL 746C for signage– FAR 25.853(a) and (d)– Class 1/A– MVSS 302– ASTM E-662/E-162

� Broad Color Selection:– 34 Standard colors– 2000+ Custom colors– Granite patterns– Fluorescent colors– Woodgrain patterns

Kleerdex Company, LLC6685 Low StreetBloomsburg, PA 17815 USATel: 1.800.325.3133Fax: 1.800.452.0155E-mail: [email protected]

ISO 9001:2000 andISO 14001 CERTIFIED

INDEX OF SPONSORS


ADVANCED VENTURES INTECHNOLOGY, INC. ................. 31

ALLEN EXTRUDERS .................... 38

AMERICAN CATALYTICTECHNOLOGIES....................... 34

ALTUGLAS INTERNATIONAL ....... 25

BROWN MACHINE ....................... 35

CMS NORTH AMERICA ................ 39

CMT MATERIALS, INC. ................. 38

EDWARD D. SEGEN & CO. .......... 36

LYLE .............................................. 20

MAAC MACHINERY ........................ 1

McCLARIN PLASTICS................... 38

McCONNELL CO. .......................... 34

MODERN MACHINERY ................ 39

ONSRUD CUTTER........................ 32

PLASTICS CONCEPTS................... 5

PLASTIMACH................................ 35

PORTAGE CASTING & MOLD,INC. ............................................ 34

PREMIER MATERIAL CONCEPTS. 34

PRIMEX PLASTICS ....................... 38

PROCESSING TECHNOLOGIES .. 38

PRODUCTIVE PLASTICS, INC. .... 34

PRODUCTO CORPORATION ....... 38

PROFILE PLASTICS ..................... 34

PROTHERM .................................. 15

RAY PRODUCTS, INC. .................. 39

RAYTEK ........................................ 27

ROBOTIC PRODUCTIONTECHNOLOGY .......................... 33

RTP ............................................... 35

SELECT PLASTICS....................... 39

SENCORP ..................................... 40

SOLAR PRODUCTS ..................... 39

STANDEX ENGRAVING GROUP .. 39

STOPOL INC. ................................ 25

TEMPCO ELECTRIC ....................... 9

THERMWOOD CORP. ...... Inside BackCover

TOOLING TECHNOLOGY, LLC ....... 5

TPS ............................................... 39

ULTRA-METRIC TOOL CO. ........... 36

WECO PRODUCTS ...................... 15

WELEX, INC. ................................. 33

XALOY .......................................... 39

ZED INDUSTRIES ......................... 38

FOXMOR GROUP ......................... 38

FUTURE MOLD CORP. ................. 39

GN PLASTICS ............................... 32

IRWIN RESEARCH &DEVELOPMENT .......................... 6

JRM INTERNATIONAL .................... 5

KIEFEL TECHNOLOGY................. 18

KYDEX .......................................... 40

LAND INSTRUMENTS .................. 34

LANXESS ...................................... 15W

e build machines that build business

Sencorp thermoformers deliver repeatable, quality production parts at high cycle speeds. Available options include closed loop thermal imaging sheet scanning, adjustable shut height, deep draw, quick changeovermaster tooling and robotic part removal systems. Sencorp thermoformers provide you with a competitive edge over your competition.

ThermoformersBlister Sealers Laboratory SealersSpecial Machines Clamshell Sealers

400 Kidds Hill Road—Hyannis, MA 02601—USAP: 508-771-9400 F: 508-790-0002 E: sales@sencorp -inc.com www.sencorp -inc.com

thermoforming 2006 16th annual thermoforming conference...to the music city. i am ready and hope to...

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