® Thermoforming Quarterly ®
A JOURNAL OF THE THERMOFORMING DIVISION OF THE SOCIETY OF PLASTIC ENGINEERS SECOND QUARTER 2011 n VOLUME 30 n NUMBER 2
The Future Is Now
Thermoforming Center of Excellence at Penn College
Workforce Development: New National Study Findings page 8 INSIDE … University News: Two Top-Tier Student Papers page 14 Sustainability: Placon Opens New Eco-Star Facility page 30
WWW.THERMOFORMINGDIVISION.COM
1TFQ 2ND Qtr 11 Cvr.indd 1 9/12/11 10:51:36 AM Thermoforming SECOND QUARTER 2011 Thermoforming Quarterly® VOLUME 30 n NUMBER 2 Quarterly® A JOURNAL PUBLISHED EACH Contents CALENDAR QUARTER BY THE THERMOFORMING DIVISION n Departments OF THE SOCIETY OF Chairman’s Corner x 2 PLASTICS ENGINEERS Thermoforming in the News x 4-5 Editor The Business of Thermoforming x 8-10 Conor Carlin
(617) 771-3321 x University News 14-17; 21-29 Page 22 [email protected]
x Thermoforming and Sustainability 30-32 BL 8(Y1) 7(Y2)Sponsorships 6(Y3) 9 (X2) MD Laura Pichon5 (X2) 10 (X1) (847)TD 829-81244 (X1) FL 1(Y1) 2(Y2) 3(Y3)
Fax Circulator(815) I.R. 678-4248 Eye Run Cooling Time Temp Temp Front Cover 1 [email protected] 2 --+ 3 -+- 4 -++ 5 +-- 6 Conference++- Coordinator The Future Is Now 7 +-+ 8 +++ Gwen Mathis
REN 2 mins 72(706) hrs 2 mins 235-9298 72 hrs Dimensions Average Average St. Dev. St. Dev. Y1 15.2772 14.7679 0.0737 0.0817
Y2 15.2703Fax 14.6292 (706) 0.0916 0.1319295-4276 Y3 15.2146 14.6189 0.1027 0.1786 X1 32.8077 32.5823 0.0680 0.0540 X2 [email protected] 32.5545 0.0604 0.0547 Z 3.6531 3.5861 0.1874 0.0854 Thickness Average Average St. Dev. St. Dev. Front 0.0728 0.0640 0.0066 0.0063 ® RightThermoforming 0.0699 0.0541 0.0072 Quarterly 0.0036 is pub- Back 0.0693 0.0590 0.0086 0.0056 Left lished 0.0733 four 0.0536 times 0.0105 annually 0.0034 as an infor- Thermoforming Center of Excellence at Penn College Top 0.1280 0.1207 0.0068 0.0037 mational and educational bulletin to the members of the Society of Plastics Engineers, Thermoforming Division, and the thermoforming1 industry. The
name, “Thermoforming Quarterly®” and its logotype, are registered trade- marks of the Thermoforming Division of the Society of Plastics Engineers, Inc. No part of this publication may be re- produced in any form or by any means without prior written permission of the publisher, copyright holder. Opinions of the authors are their own, and the n publishers cannot be held responsible In This Issue for opinions or representations of any unsolicited material. Printed in the Save the Date - 2011 Conference x 19 U.S.A. Council Summary x 33 Thermoforming Quarterly® is regis- tered in the U.S. Patent and Trademark Office (Registration no. 2,229,747). x Page 33 Cover Photo courtesy of Penn College www.thermoformingdivision.com All Rights Reserved 2011
Thermoforming QUARTERLY 1
1TFQ 2ND Qtr 11 ins.indd 1 9/12/11 11:31:39 AM Thermoforming Chairman’s Corner Quarterly® Committed to the
Ken Griep Next Generation
The Center has received $10,000 The second presentation was in seed money from your division given by Aaron Lapinski, entitled along with $50,000 for equipment. “Thermoforming ABS for In addition, the SPE Foundation Dimensional Consistency.” This has donated $10,000. Several board project was aimed at mold comparison members, Mark Strachan and Jay in which dimensions, shrinkage uring the past 4 years, your Waddell, deserve special recognition and mechanical properties of Dboard has been engaged in a major for their contributions to the Center. thermoformed ABS were compared on undertaking to help fund and develop MAAC Machinery continues to two different mold types. The purpose The Thermoforming Center of deliver equipment for educational of this project was to demonstrate Excellence at the Pennsylvania College purposes. Finally, I want to offer a to the thermoforming industry that of Technology in Williamsport, PA. special word of thanks to Roger Kipp a temperature-controlled mold is We recently returned from our Spring and McClarin Plastics for all the hours essential for maintaining dimensional board meeting which was held on the and devotion to the success of this consistency in the finished product. campus. On behalf of the board, I want important project. to thank Dr. Hank White, Director It is critical that our industry of the Center, as well as the staff It is truly remarkable to see these understand the importance of training members of PCT for their hospitality young men and women roll up their the next generation of toolmakers, during our visit. I am pleased to report sleeves and get directly involved in designers and machine operators. Understanding the manufacturing that the future of our industry looks all elements of the thermoforming process is key to maintaining a promising. process: developing working models, competitive edge and should not be running detailed experiments and The Center is by far the most overlooked as the core of this new producing high-quality technical technologically advanced center workforce enters the job market. papers. Two such papers appear in this dedicated to the art and science of This should be a primary goal for all issue of the Quarterly as a testament plastics processing. The facility thermoforming companies. As our to our continued focus on workforce offers services in material testing, industry grows, we need to bring development. weather testing and analysis, as well in new, educated and trained talent as material compounding. The board that is equipped with the tools and “Thermoforming High Density members were also able to see the knowledge to advance our industry for Polyethylene Sheet Using range of processing capabilities on years to come. Temperature-Controlled Aluminum display, including injection molding, Tooling,” presented by Brett rotational molding, sheet and film Thank you for your continued Braker, illustrated the differences manufacturing, blow molding and, support and get the word out – Do of thermoforming HDPE using naturally, thermoforming. The Thermoforming! temperature-controlled and non- thermoforming machine is a MAAC temperature-controlled tooling. In so Machine Model 43SPT, a 36" x 48" Please feel free to contact me with doing, the paper aimed to prove that Single Station Pressure Former with your views and comments. I would Twin Sheet capabilities and 3rd motion HDPE can be used with success in like to hear from you! the thermoforming industry as long plug assist. This machine will give the [email protected] students first-hand, practical expertise as temperature controlled aluminum on processing, machinery operation tooling is used. and material testing.
2 Thermoforming quarterly
1TFQ 2ND Qtr 11 ins.indd 2 9/12/11 11:31:47 AM Thermoforming New Members Quarterly®
Greg Hart Peter Rye Robert M. Stack C. Matthew Brown Marc Tangway Global Tool & Automation Brentwood Industries Hasbro Inc. Poly Flex Products Bainultra Corporation Inc. East Longmeadow, MA Knoxville, TN Saint-Nicolas, QC, Laotto, IN Reading, PA Canada Aleesha P. Pruett Martin Bollands Mark Haworth Donald A. Berrill Capitola, CA Seaborne Plastics Ltd. Spartech Plastics Michada Resources Cranleigh, United La Mirada, CA Cambridge, ON, Canada Kingdom
Andrew Horsman John Keirstead Otario Tire Stewardship WAL Consulting (HK) Ltd. Toronto, ON, Canada Leduc, AB, Canada
Marty Rodriguez Michel Labonte Printpack Inc. Montreal, QC, Canada Williamsburg, VA Why Join? Matt C. Smallwood Aaron J. Lapinski Pittsburg State University Pennsylvania College of Pittsburg, KS Technology Bloomsburg, PA Bill Goldfarb Universal Dynamics Inc. Joe McCaleb Woodbridge, VA Heritage Plastics Atlanta, GA Ted Bickel amros industries, inc. Wendell Gabbard Cleveland, OH It has never been more important to Stone Plastics, Inc. be a member of your professional Cadiz, KY Joan Ruiz ESCAURE IBERICA, S.A. society than now, in the current Mathew P. Barr Sta Perpetu Mogoda, climate of change and volatility in Faurecia Interior Systems Spain Auburn Hills, MI the plastics industry. Now, more than Jody M. Morrow ever, the information you access and Jon Larson GoodVillage Foundation Krones Inc. Friendship, WI the personal networks you create Franklin, WI can and will directly impact your Rhonda L. Funmaker Antonio Marcucci GoodVillage Foundation future and your career. Poly-Vac Friendship, WI Sao Paulo, Brazil Adriane Wiltse Active membership in SPE – keeps Jim Dolan Plastic Engineer J&J Performance Powder Pittsburg State University you current, keeps you informed, Coating Midland, TX and keeps you connected. Carlock, IL Brett Landen Wehner Aster Teo Weco International Inc. The question really isn’t Milliken Asia Pte Ltd. Clio, MI Singapore “why join?” Justin Fowler but … Brian Cristea Dart Container International Automotive Corporation Components Mason, MI Troy, MI Brian Tidwell Polyvel Inc. Why Not? Hammonton, NJ
Thermoforming QUARTERLY 3
1TFQ 2ND Qtr 11 ins.indd 3 9/12/11 11:31:48 AM Thermoforming in the News
Chinese Computer The plastic cushions he removed that this was clearly a copied seemed almost identical – except product,” he said. He forwarded Giant Accused of that “they had just cut the top off” the photos to a patent agent, who Stealing Packaging – to those made by the company agreed. Then he got a lawyer and Patent that Doyle works for, Reflex started talking to Lenovo. Packaging. And they came with Reflex Packaging one of Reflex’s main customers, Lawsuit Filed says Lenovo stole Lenovo. But they weren’t made intellectual property by Reflex. Similar incidents Reflex Packaging By Matthew Robertson, Epoch Times, began occurring around Forrest designs and produces March 29, 2011 Smith, general manager of the thermoformed cushions for firm and inventor of the packaging packaging fragile goods, like enny Doyle was out on a patent. People he knew who had computers and hard drives. Kroutine sales call in southern just purchased a Lenovo PC would Thermoforming is a process California when he noticed email him asking “When did you that uses heat and pressure something odd in the corner. The start making your parts in green?” to make plastics; Smith uses customer he was visiting had just recycled plastics, and Lenovo has purchased new computers for the He hadn’t. And now he is suing won environmental awards for office, and the packaging was in Lenovo – China’s largest personal using his products. the trash heap. computer manufacturer, and fourth largest in the world (its income For around 30 years the “Something caught my eye,” was $16.6 billion in 2010) – for primary means of shipping he says, as he looked at the stealing his design. When he saw computer parts had been foam. “We plastic cushions used to protect the pictures, “I thought, ‘Great, were the first to take a thermoform they took our product and made the computers when they’re part and make a cushion that was some modifications to it and inside the cardboard boxes. able to function,” Smith said. started producing it,’ ” he said in a “It was a different color and it Reflex had been “grandfathered” telephone interview. “There was no looked different to me,” he said. into Lenovo’s supply chain when doubt in my mind, as the inventor, “They were Lenovo boxes.” the Chinese company came out of nowhere to buy IBM’s computer division for U.S. $1.75 billion in 2005. Business was coasting along comfortably, at the rate of 5-10 thousand systems per week, with Reflex supplying the patented cushions – until around 2008, Smith recalls.
Every year, typically, computer companies spruce up their product ranges. With new designs comes the need for new cushions to SPOT THE DIFFERENCE: Lenovo’s alleged copy (L) alongside the product patented by Forrest protect them when shipping. Smith of Reflex Packaging (R). Smith says it is obvious that Lenovo in China simply copied his design. Lenovo says there are many differences between them. (Courtesy of Reflex Packaging) Usually Smith talks with Lenovo
4 Thermoforming quarterly
1TFQ 2ND Qtr 11 ins.indd 4 9/12/11 11:31:49 AM personnel about the fresh specs. worked at Lenovo all he did was succeed in the domestic market But in 2008 the conversation tell Reflex the weight and sizes of before launching out to tackle the went slightly differently. Lenovo the computers, for testing. “The global competition. The Chinese wanted Reflex to remove its guys in China were saying just communist leadership wishes name and patent number from the stuff that a normal person would to stake out key commercial products. Smith didn’t consent think, ‘What? That’s crazy, what territory for Chinese companies, to the second part, “so they are you talking about?’ ” Smith Ling writes, and Liu Chuanzhi, stopped doing business with us said. the founder of Lenovo and and started their own version,” “godfather” of China’s IT he says. Reflex’s business with Lenovo in the U.S. did not return industry, was able to market the computer giant in China has calls or emails requesting they himself in that mold. He won the clarify the matter when contacted essentially “been eliminated.” support from Party leaders crucial by The Epoch Times. Smith says He believes that Lenovo simply for his business’s success. he is not exactly upset, but that “the took his patent to a thermoform blatancy of it kind of aggravated manufacturer in China and got The official connection me.” Aside from what he sees as them to make something very the brazen theft, he was roused by is particularly galling to similar. A year later Lenovo was something else. “The commentary Congressman Dana Rohrabacher shipping its products to the U.S. from our counsel over in China was (R-CA), a long-term crusader using stolen intellectual property, even more frustrating, which was against Chinese predations Smith says. The case was filed that your odds of suing successfully against American companies. with the California Northern in China because of this are very “You have a situation where District Court in March 2010, after low, because Lenovo is one of the private companies are doing discussions broke down. The local ‘great sons of China.’ That was the this, and that’s bad enough, but Orange County Register reported message that I got back.” to know that companies where on the story. the government has a stake are Lenovo has close ties with the directly engaged in these types “Outrage” Chinese Party-state. It is held up as of predatory practices, it makes it a model of China’s development, even worse,” he said in a phone When a customer sues its buyer, an ideal “China Story,” writes the interview. He added: “When the that’s usually the end of the author Ling Zhijun in her book public learns the full details about relationship, “but on the other “The Lenovo Affair.” Originally what’s going on to American hand, you have to protect your a state-owned entity, it was later companies … we’re going to property or else anyone will walk spun out as a private concern, but have not just upset but outrage.” in and take it,” Smith said. The the regime still owns the largest legal process is moving “painfully share and exerts control. The Smith plans to pursue legal action slow” for Smith. “We’re probably company became well-known in in other countries that Lenovo the West only after its bold 2005 right in the middle of the case ships to. Ideally he would like acquisition of IBM’s personal against them,” he said. The two them to stop copying the product computer business, which it soon parties are combing the minutiae of and buy it from him instead. resuscitated and spring-boarded each other’s claims before the case Failing that, the court may from. The IBM buy-out was goes to trial. only be able to stop the product understood within China as a entering the United States. “powerful blow” to the “plot by Lenovo, in emails to Smith, said Lenovo has presented several global Western enterprises” to take that there are many differences versions of events. Initially they over the Chinese computer market, said that one of their own people, Ling writes. It makes Lenovo, or between the two products. packaging engineer Christopher Lianxiang in Chinese, a standard They wrote: “We all respect Sattora, was involved in the bearer among the new cohort of and protect your intelligence and product development. But when he nationalist Chinese companies that work.” x
Thermoforming QUARTERLY 5
1TFQ 2ND Qtr 11 ins.indd 5 9/12/11 11:31:50 AM PROSPECTIVE AUTHORS Thermoforming Quarterly® is an “equal opportunity” publisher! You will notice that we have several departments and feature articles. If you have a technical article or other articles you would like to submit, please send to Conor Carlin, Editor. Please send in .doc format. All graphs and photos should be of sufficient size and contrast to provide a sharp printed image.
6 Thermoforming quarterly
1TFQ 2ND Qtr 11 ins.indd 6 9/12/11 11:31:55 AM Need help with your technical school or college expenses?
f you or someone you know is Iworking towards a career in the plastic industry, let the SPE Thermoforming Division help support those education goals. Within this past year alone, our organization has awarded multiple scholarships! Get involved and take advantage of available support from your plastic industry! Here is a partial list of schools and colleges whose students have benefited from the Thermoforming Division Scholarship Program: • UMASS Lowell • San Jose State • Pittsburg State • Penn State Erie • University of Wisconsin • Michigan State REDUCE! REUSE! RECYCLE! • Ferris State • Madison Technical College • Clemson University • Illinois State • Penn College Start by completing the application forms at www.thermoformingdivision. com or at www.4spe.com. x
Thermoforming QUARTERLY 7
1TFQ 2ND Qtr 11 ins.indd 7 9/12/11 11:32:00 AM Thermoforming The Business of Thermoforming Quarterly®
he National Study of The following is excerpted from a comprehensive study on workforce development conducted TBusiness Strategy and by The Sloan Center on Aging & Work at Boston College. We are grateful to the authors for giving us permission to reprint the main findings in this issue Thermoforming Quarterly which Workforce Development features technical articles from students of thermoforming science and process. As the division surveyed organizations about chairman states in his remarks, the success of our industry depends on our ability to attract and their responses to the aging retain a new generation of practitioners. workforce including the adoption of a range of flexible work Selected Findings to encourage early career employees to remain with the options. Information was gathered Phase I organization as did the 29% about a range of factors that could Phase I of the National Study of who indicated that it was explain variation in workplace Business Strategy and Workforce important “to a moderate or responsiveness, including: Development surveyed a great extent” to encourage late characteristics of the business benchmark sample of employers career employees to remain environment, priority business responding to the aging workforce. strategies, HR challenges, with the organization. • 41% of the respondents workforce development, • The top three HR challenges and workplace culture and indicated that their companies “to a moderate/great extent” workforce demographics. Data had analyzed their workforce noted by the Benchmark were collected to distinguish demographics “to a great employers were: providing “early adapters” from other extent.” effective supervision, organizations. • On average, these Benchmark knowledge transfer, and employers noted that they recruiting competent job Key Research expect that 15% of their applicants. Despite the fact Questions employees will retire over the that 59% of the Benchmark next four years. organizations reported • To what extent have that knowledge transfer is employers considered if/how • 61% of the respondents a challenge, a substantial the aging of the workforce indicated that age diversity is proportion (approximately might affect their business important to their organizations two of every five) had either operations? “to a great extent,” compared not developed processes to • What steps have employers to the 83% who indicated transfer institutional memory/ taken – including the that gender diversity is that knowledge “at all” or had only implementation of flexible important and the 78% who developed these processes “to a work options – to recruit, reported that cultural diversity limited extent.” engage, and retain talented is important. Employers • More than half of the employees at different career were also more likely to respondents to the Benchmark stages? indicate that it is important “to a great extent” to recruit Study felt that: Early-career • Do employers see employees with diverse cultural employees tend to take relationships between their backgrounds and to recruit both initiative and be creative; key business strategies and men & women than to recruit mid-career employees tend different approaches to talent employees of diverse ages. to be loyal to the company, management, including the be productive, be reliable, engagement of late-career • Twice as many of the have established networks of employees? Benchmark employers (64%) professional colleagues, and indicated that it is important have high skills relative to “to a moderate or great extent” what is needed for the job; 8 Thermoforming quarterly
1TFQ 2ND Qtr 11 ins.indd 8 9/12/11 11:32:01 AM and late-career employees policies; no productivity payoff from time to time; choose a tend to take initiative, be loyal anticipated; not cost-effective; schedule that varies from the to the company, be reliable, concerns about increased typical schedule at the work have established networks of absenteeism; concerns about site; have some control over professional colleagues, have treating all employees equally; when to take a break; and take high skills relative to what is the organization has other more extended leave for caregiving. needed for the job, have strong pressing business issues. work ethics, and have low • Employers are beginning Phase II turnover rates. to make a link between Phase II of the National Study of flexibility options and their • 50% or more of the Benchmark Business Strategy and Workforce core business. More than employers indicated that the Development surveyed a more half of employers (55%) link following flexible work options representative sample of United workplace flexibility and are available to their full-time States businesses. overall business effectiveness employees: request changes in • Only a minority of employers to a “moderate” or “great” starting and quitting times on a in the National Study (34%) extent. daily basis; reduce their work reported that their organization hours and work on a part-time • Employers’ motivations had made projections about basis while remaining in the for flexibility varied, but retirement rates of their same position or at the same key motivators included: employees to a moderate level; control when they take (percentage agrees to a or great extent. One-fourth breaks; and choose a work moderate or great extent) (26%) reported that their schedule that varies from - To increase employees’ organizations had not analyzed the typical schedule at their commitments and job the demographics of their organizations. engagement (67%) workforces at all. In contrast, • 45% of male workers aged only 12% felt that their - To do the right thing for 50 or older have access to organizations had analyzed your employees (66%) guaranteed benefits plans at their workforce demographics - To improve morale (63%) work in comparison to the 35% to a “great extent.” of the females. - To help retain highly skilled • Since older workers’ prefer employees (62%) • Approximately one of every flexible work options, it is five of the Benchmark important that employers - To retain employees, in respondents state that their also acknowledge the key general (61%) organizations link workplace role of workplace flexibility - To increase productivity flexibility to overall business in recruiting and retaining (61%) effectiveness “to a great employees of all ages. More extent” with another half (47%) than half of employers (59%) - To help employees manage indicating that this link is made indicated that flexible work work and family life (60%) “to a moderate extent.” options were available for their • When it comes to retention • The barriers to flexibility employees to a “moderate” or and recruitment of older identified by 50% or more of “great extent.” employees, again only a the Benchmark respondents • The flexible work options minority has taken the lead: included: implementation offered by the highest Only 37% of employers costs too much; administrative percentage of employers to had adopted strategies to hassles; concerns about possible “most/all” of their full-time encourage late-career workers employee complaints or employees include employees’ to stay past the traditional liability; employees don’t seem ability to: request changes in retirement age. Less than to want these programs and starting and quitting times (continued on next page)
Thermoforming QUARTERLY 9
1TFQ 2ND Qtr 11 ins.indd 9 9/12/11 11:32:01 AM one-third of respondents extent to which these options reporting more motivators for (31%) indicated that their are available to employees in adopting flexible work options. organizations adopted the workforce). Along with selected control practices to recruit employees • Factors that predict the scope variables, these variables of diverse ages to “a great of workplace flexibility explain 26% of the variance in extent.” include: having conducted workplace flexibility. • Employers identified career analyses of their workforces • Although perceptions of union stages defined by three sets (e.g., demographic analyses, considerations (as a barrier) are of factors: education and projections of retirement, and not a statistically significant training; prior experience; and examination of employees’ predictor of the scope of intention to pursue work in career plans); having top flexible work options, union their career. managers aged 65 and presence is related to a more older; having a “culture of • Employers associated age limited scope of workplace commitment” with regard ranges with career stages: flexibility. x to workplace flexibility; and early career employees (ages 21-38); mid-career employees (ages 31-47); and late career employees (ages 46-53). It is important to note that these stages and ages overlap, suggesting permeable boundaries between stages. • Employers said that late- career employees, “have high levels of skills and strong professional and client networks, a strong work ethic, low turnover, and are loyal and reliable.” In addition, contrary to some stereotypes of older workers, similar percentages of employers felt it is “very true” that late-, mid-, and early-career employees take initiative. And a similar percentage of employers felt it was “very true” that early-, mid-, and late-career employees are productive. • Professional services firms and social service agencies are two industry sectors that offer a greater scope of workplace flexibility (taking into consideration the number of flexible work options and the
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1TFQ 2ND Qtr 11 ins.indd 10 9/12/11 11:32:16 AM Thermoforming QUARTERLY 11
1TFQ 2ND Qtr 11 ins.indd 11 9/12/11 11:32:25 AM
Society of Plastics Engineers Thermoforming Europe Division Eric Sasselaan 51 ~ BE-2020 Antwerpen ~ Belgium Tel. +32 3 541 77 55 ~ Fax +32 3 541 84 25 [email protected] ~ www.e-t-d.org
First Announcement & Call for Papers 8th European Thermoforming Conference
Organized by SPE Thermoforming Europe Division
Thursday 26 April – Friday 27 April 2012 Venice, Italy
The European Thermoforming Division of the SPE has commenced its preparation for the 8th Thermoforming Conference which will be held in Venice, Italy.
The highly successful parallel commercial presentation session in Antwerp will again be included in Venice. This is in recognition of member feedback which valued the commercial track. This programme allows each sponsor an open forum to present their new developments to the conference attendees for duration of 5 minutes. This opportunity complements their marketing strategy at the event adding yet more value to the package.
It is important for us as organizers and for the thermoforming industry as a whole to benefit from this event. In order to do so, we need to ‘tailor’ it in the most efficient and economical fashion. You can help us do that by indicating the likelihood of your sponsorship involvement. We stress that this response would be recognised as an indicator only and would not constitute a firm commitment at this stage.
The main technical lecture programme is under development and promises to be the best ever with a number of eminent speakers already agreeing to participate.
Intention to submit a paper should be communicated to the Conference Secretariat as soon as possible. Please include the prospective title and a general outline of the work. Authors are invited to provide an abstract (300 words maximum) of their paper before 30 August 2011 by email [email protected] or by fax +32 3 541 84 25.
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1TFQ 2ND Qtr 11 ins.indd 12 9/12/11 11:32:26 AM From the Editor If you are an educator, student or advisor in a college or university with a plastics program, we want to hear from you! The SPE Thermoforming Division has a long and rich tradition of working with academic partners. From scholarships and grants to workforce development programs, the division seeks to promote a stronger bond between industry and academia. Thermoforming Quarterly is proud to publish news and stories related to the science and business of thermoforming: • New materials development • New applications • Innovative technologies ISO 9001:2000 • Industry partnerships • New or expanding laboratory facilities • Endowments We areJuliet also Oehler interested Goff, President/CEO, in hearing Kal from Plastics our members and colleagues around the world. If your school or institution has an international partner, please invite them to submit relevant content. We publish press releases, student essays, photos and technical papers. If you would like to arrange an interview, please contact Ken Griep, Academic Programs, at: [email protected] or 608.742.7137
REDUCE! REUSE! RECYCLE!
REDUCE! REUSE! RECYCLE!
Thermoforming QUARTERLY 13
1TFQ 2ND Qtr 11 ins.indd 13 9/12/11 11:32:45 AM University News
MET 496 Senior Project Thermoforming ABS for Dimensional Consistency: Effects of Temperature versus Non-Temperature Controlled Tooling
Aaron Lapinski, Pennsylvania College of Technology, Williamsport, PA
Abstract Procedure This project was a mold comparison project The first stage of this project was to obtain a in which dimensions, shrinkage and mechanical temperature controlled aluminum which was supplied properties of thermoformed ABS were compared by McClarin Plastics, Inc. The next step was to obtain a on two different mold types. The two molds are a non temperature controlled mold with the same shape and temperature controlled aluminum mold and non dimensions. The non temperature controlled Ren shape temperature controlled Ren Shape mold. A design of mold was supplied at no charge by Tooling Technology. experiment (DOE) was also preformed on this project. The Ren shape mold is a Ren Shape 472 Medium- The purpose of this project is to demonstrate to the Density high temperature Polyurethane Fixture Board thermoforming industry that a temperature controlled mold. The next step was to obtain the ABS material mold is essential for maintaining dimensional for my project. The material that obtained was 1/8 inch consistency in the finished product. ABS; it was supplied at no charge by Spartech Plastics. The sheets needed to be prepared for the forming study. Introduction First, a 1-inch-by-1-inch grid was marked on the back In the thermoforming industry high part of the sheet. The sheet was then dried at 180o F. for 24 dimensional variation has always been a problem. hours before forming. The sheets were dried off-site at This project will demonstrate that the specification Kydex LLC. range on thermoformed parts doesn’t need to be near as wide as it is. The scope of this project is to determine Once the sheets were dried, the Ren Shape mold was the effects of using temperature controlled aluminum centered and hung on the top platen to better help utilize mold with and a non temperature controlled Ren Shape the sag of the heated sheet. This was done by placing the mold on an industrial size MAAC thermoformer. The mold upside down on the bottom on platen and sliding variables being evaluated are part quality, dimensions, it until the clamping rails could be set symmetrically shrinkage, and cycle time on amorphous ABS sheets around the mold. Then a new cycle to form the best of the same color and thickness. possible part needed to be created. The MAAC machine parameters for this cycle were an infrared eye setting of My project has four basic goals. The first is to o determine how a temperature controlled aluminum 360 F. for the sheet temperature, the heating time was mold and non temperature controlled Ren Shape set to 120 seconds, forming time was set to 100 seconds, mold of the same dimensions will affect shrinkage ejection time was set to 2 seconds, the vacuum pressure of a thermoformed ABS part. The second is to was 24 in Hg and the ejection pressure was 5 psi. gain experience on the set up and operation of the industrial scale MAAC thermoformer. A third goal After creating a good cycle, I began forming parts. for this project is to develop a thermoforming lab The first study was a production run of thirteen samples. experiment on the MAAC thermoformer for student The first three samples were to allow everything to education in Pennsylvania College of Technology’s equilibrate and then I collected data on the next 10 BPS program. The fourth is to demonstrate to the samples. thermoforming industry that a temperature controlled mold is essential for maintaining consistency in the The data that was collected included humidity, finished product. room temperature, mold front, mold back, mold top,
14 Thermoforming quarterly
1TFQ 2ND Qtr 11 ins.indd 14 9/12/11 11:32:46 AM sheet temperature at molding, sheet temperature at de- the best part while also creating the least amount of molding, and clamp temperature. Once the production dimensional change. The variables were cooling time, run was done, I collected dimensional data from each circulator temperature, and I.R. eye temperature. part. Dimensional data included height, length, width, and thickness. After 24 hours the dimensions were re- After completing all the forming, ASTM D638 measured in the same way which showed how much Type 1 tensile specimens were die cut out of each the part had shrunk. The measurements were taken side of the first, fourth, seventh, and tenth part on both using a specially designed measurement jig to better production style runs. These were used to evaluate and assure that each part was measured consistently. compare the tensile strength in both the machine and transverse direction through the cycles. The gauge After the REN production style run samples were length for the samples was set to two inches. The formed and measured, the REN mold was removed ASTM method D638 – 10 was followed during the and replaced by the aluminum mold. The next study tensile testing. The load cell usedHigh was 25 KN Lowand the was done on the aluminum mold. The same data was extensionCooling rate wasTime 0.2 in/minute.100 A laser extensometer40 collected for this run as for the REN production style was placedCirculator opposed Temp to the test 205specimens which170 had run. There were a few differences that needed to be reflectiveI.R. tapeEye Temp placed two inches400 apart; the 340purpose I.R. Eye made to the cycle with the aluminum mold to be able of the laserRun extensometerCooling Time was Circulatorto more Temp accurately Temp to achieve acceptable parts. The first of these changes measure the elongation and modulus values. was to increase the infrared eye setting from 360o F. 1 - -- to 380o F. The other change that was made was the 2Materials - -+ reduction in the cooling time from 100 seconds to 55 3 - +- The material4 that was - used to ++ conduct this seconds. This was done because at any time longer than experiment5 was Acrylonitrile + Butadiene -- Styrene 55, the samples cooled too much and began sticking (ABS). The6 ABS is a + 1/8-inch thick +- premium to the mold. Due to the decrease in cooling time total 7 + -+ grade, natural polish, and was supplied by Spartech cycle time is then in turn shortened. This can is very 8 + ++ Plastics. beneficial for increasing production rates.
A design of experiment (DOE) was also preformed on the aluminum mold. The DOE contained two levels The molds that were used are an aluminum mold and three factors, so it was considered a 2x3 factorial experiment. The design of experiment can be noticed supplied by McClarin Plastics Inc. and a Ren Shape below in Figure 1. 472 Medium-Density high temperature Polyurethane Fixture Board mold supplied by Tooling Technology. High LowLow Cooling Time Cooling Time 100 40 40 Circulator Temp The machine used was a custom manufactured Circulator Temp 205 170170 . I.R. Eye Temp 400 340 MAAC thermoformer, model number 43SPT. The I.R. Eye Temp 400 340 I.R. Eye circulator that was used is a Sterlco VISION 4410-C Run Cooling Time Circulator Temp Temp with a maximum temperature of 250° F. Tensile 1 - -- testing was performed on a Tinius Olsen H25KS. 2 - -+ 3 - +- Results
4 - ++ This was a very successful project in terms of my 5 + -- 6 + +- project objectives. The data shows that the samples 7 + -+ collected from the aluminum mold exhibit much 8 + ++ more stable dimensions than samples collected from
Figure 1 shows the variables that were chosen for the DOE. It the non temperature controlled Ren Shape mold; this also shows the parameters that were chosen for these variables. can be seen in Figure 2, Figure 3, Figure 4, and Figure 5 (shown on the next page). The purpose of the DOE was to gain valuable data that would show which cycle parameters created (continued on next page)
Thermoforming QUARTERLY 15
1TFQ 2ND Qtr 11 ins.indd 15 9/12/11 11:32:48 AM
.
High Low
Cooling Time 100 40 High Low Circulator Temp 205 170 Cooling Time 100 40 I.R. Eye Temp 400 340 Circulator Temp 205 170 I.R. Eye I.R.Run Eye Temp Cooling Time400 Circulator Temp 340 Temp I.R. Eye Run Cooling Time CirculatorHigh Temp Low 1 - --Temp Cooling Time 100 40 12Circulator Temp -205 -+--170 3 - +- 2I.R. Eye Temp -400 -+340 4 - ++ 3 - +-I.R. Eye 5Run +Cooling Time -- Circulator Temp 4 - ++Temp 6 + +- 5 + -- 71 + - -+ -- 6 + +- 8 + ++ 72 + - -+ -+ 83 + - ++ +- 4 - ++
5 + -- 6 + +-
7 + -+ 8 + ++
Thickness differed an extreme amount between the Ren shape mold and the aluminum mold. The thicknesses from the top of the sheets that were removed from the Ren shape mold were much greater than the
thicknesses. of the sides of the same sheet. This may be due to the differences in thermal conductivity between . aluminum and Ren material. The thermal conductivity of aluminum is 144.447 Btu (IT) foot/hour/square foot/° F. and for Ren material or Polyurethane it is only 0.011556 Btu (IT) foot/hour/square foot/° F. . Figure 2 shows the difference in width between the aluminum mold at 2 minutes after forming and then 24 hours after forming.
Figure 6 shows the difference in the thickness throughout the parts on both the aluminum mold and the Ren shape mold. Figure 3 shows the difference in width between the Ren shape mold at 2 minutes after forming and then 24 hours after forming. Another variable that was noticed is an increase in mold temperature and sheet temperature at de- High Low molding. The increase in temperature explains why the High Low Cooling Time 100 40 dimensions of the parts on the Ren shape mold vary CirculatorCooling Time Temp 100205 17040 so much more than the dimensions of the parts from CirculatorI.R. Eye Temp Temp 400205 340170 the aluminum mold; this can be noticed in Figure 7 I.R. Eye Temp 400 I.R.340 Eye Run Cooling Time Circulator Temp I.R. Eye (below) and Figure 8 (shown on the next page). As the Run Cooling Time Circulator Temp Temp Temp mold temperature increased, bumps around the edges 1 - -- 1 - -- of the sheets began to form especially on the back of 2 - -+ the sheet, towards the ovens. The bumps were actually 32 - +--+ 43 - +-++ blisters or bubbles that were caused by either uneven
54 + - ++-- heating or too rapid heating. Figure 4 shows the difference in length between the aluminum mold 65 + +--- at 2 minutes after forming and then 24 hours after forming. 76 + +--+ 7 + -+ 8 + ++ 8 + ++
Figure 7 shows the temperature of the front, back, and top of Figure 5. shows the difference in length between the Ren shape mold the aluminum temperature controlled mold. It also shows the at 2 minutes . after forming and then 24 hours after forming. temperature of the sheet temperature at de-molding.
16 Thermoforming quarterly
1TFQ 2ND Qtr 11 ins.indd 16 9/12/11 11:32:55 AM
controlled aluminum mold is essential in the case of ABS at the very least, to producing thermoformed parts with predictable and consistent dimensions.
This project outcome portrays vital information to the thermoforming industry and should be greatly considered when designing and purchasing molds for the production of thermoformed parts. x
References
Figure 8 shows the temperature of the front, back, and top of “Acrylonitrile, Butadiene and Styrene (ABS) -
the Ren shape mold. It also shows the temperature of the sheet FormTight Plastic Thermoforming.” Custom temperature at de-molding. Packaging - Clamshells, Food Packaging, Blister The DOE showed which settings were the correct Packaging - FormTight Plastic Thermoforming. settings, it also showed which settings yielded the most Web. 27 October 2010.
Thermoforming QUARTERLY 17
1TFQ 2ND Qtr 11 ins.indd 17 9/12/11 11:32:56 AM 18 Thermoforming quarterly
1TFQ 2ND Qtr 11 ins.indd 18 9/12/11 11:33:02 AM Thermoforming QUARTERLY 19
1TFQ 2ND Qtr 11 ins.indd 19 9/12/11 11:33:10 AM 2011 EDITORIAL CALENDAR Quarterly Deadlines for Copy and Sponsorships ALL FINAL COPY FOR EDITORIAL APPROVAL SAVE THE DATE! 15-FEB Spring 30-APR Summer October 16 thru October 19, 2011 31-JUL Fall 15-NOV Winter Westin Peachtree Plaza Hotel Conference Edition Post-Conference Edition
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20 Thermoforming quarterly
1TFQ 2ND Qtr 11 ins.indd 20 9/12/11 11:33:18 AM Thermoforming High Density Polyethylene Sheet Using Temperature-Controlled Aluminum Tooling
Brett K. Braker, Pennsylvania College of Technology
Abstract variation a non temperature-controlled mold will. This will give the company much needed control of Previous research has shown that thermoforming the tooling to help give them a chance at producing high density polyethylene (HDPE) is something that better quality parts for their customers. With better has been shied away from in the plastics industry. This quality parts coming off of the temperature-controlled paper will show the differences of thermoforming HDPE mold, there will be much less scrap sheet, stabilized using temperature-controlled and non temperature- cycle times and oven temperatures, and the company controlled tooling. In doing that, it will aim to prove that will be paying the cost of the tooling off with material HDPE can be used with success in the thermoforming savings. industry, as long as temperature controlled aluminum Temperature-controlled tooling opens the doors tooling is used. to numerous materials that were once thought to never have a place in the thermoforming industry. It Individual Performance minimizes the increase in percent crystallinity that a Objectives material goes through when it is heated up and let to 1. Show the importance of temperature-controlled relax. molding in thermoforming. Material 2. Prove that HDPE can be a relevant material to use in thermoforming, instead of just amorphous materials. Black HDPE sheet was used for this project. The sheet was 40 inches wide (machine direction), 22.5 Introduction inches long (transverse direction), and 0.125 inches thick. The material has a levant finish on one side and High density polyethylene isn’t usually thought a smooth finish on the other, which would be the side of as a usable material when thermoforming is talked used to touch the mold. The HDPE should be formed about. It is not a material that seems like it would work in between 285 and 385 degrees Fahrenheit, with the with that type of process. Companies in industry have optimum forming temperature being 330 degrees shied away from HDPE, because of its crystallinity Fahrenheit. The optimum temperature to take the and shrinkage rate. The thermoforming industry almost sheet out of the mold is 170 degrees Fahrenheit. always uses amorphous materials, because they are a Thermoformable high density polyethylene sheet lot easier to control than crystalline materials. has an average density of 0.0345 pounds per inch Also, a lot of companies use wooden or urethane cubed (0.955 grams per cubic centimeter). It also has tooling to run their parts, because it is a lot cheaper to a 66.3 average Shore D Hardness, an average ultimate do that than to get aluminum or steel tooling. Instead of tensile strength of 3,800 pounds per square inch (psi), heating up their mold with water or oil, and keeping it at and an average tensile yield stress of 3,829 psi. The a constant temperature, they will just let the heat of the average deflection temperature with 66 psi is 166.5 machine and material heat up the mold over time, but degrees Fahrenheit. will run into problems at the start and end of their runs. The mold will either be too cold for the material and Procedure cool it too quickly, or be too hot, which will lengthen cycle time, and increase the chances of part defects. This project started when the material was received Increased cycle times and part defects will cost the from the manufacturer. The first step after receiving company a lot of money in the long run, when they the material was to put a grid system on the smooth could’ve just used a temperature-controlled aluminum side of the sheet, so that it could be measured to show mold. A temperature-controlled mold will stabilize the stretching that the material goes through when it mold temperature from the start, and will not have the (continued on next page)
Thermoforming QUARTERLY 21
1TFQ 2ND Qtr 11 ins.indd 21 9/12/11 11:33:19 AM
is formed. With help from the Printing Department because the sag in the pliable material coming from the BL 8(Y1) 7(Y2) 6(Y3) at Penn College, the sheet was screen printed with oven coinciding with the top of the cool mold would 9 (X2) MD 5 (X2) an inch by inch silver grid system (shown in Figure cause a build-up of material in the four corners where 1). After the gridding was complete on the 50 HDPE the material would drape over the side of the mold. sheets that were available for the project, they were Switching to the top platen (shown in Figure 3) would 10 (X1) TD 4 (X1) ready to be thermoformed. The first mold that was eliminate the build-up of material in the corners, and FL 1(Y1) 2(Y2) 3(Y3) create a better quality part. to be used on the project was a replica mold of the main aluminum mold for the project, and it was made Circulator I.R. Eye Run Cooling Time out of Renshape 472 medium-density Polyurethane Temp Temp Modeling Board. The mold has a wooden base, and 1 - -- then the machined polyurethane is made to be exactly 2 - -+ the same dimensionally as the aluminum mold, which 3 - +- in relation to the material, is 15.25 inches long, 33.125 4 - ++ inches wide, and 4.2 inches high. 5 + -- 6 + +- 7 + -+ 8 + ++
REN 2 mins 72 hrs 2 mins 72 hrs Dimensions Average Average St. Dev. St. Dev. Y1 15.2772 14.7679 0.0737 0.0817 Figure 3. Renshape mold on top platen. Y2 15.2703 14.6292 0.0916 0.1319 Y3 15.2146 14.6189 0.1027 0.1786 Also by switching to the top platen, counter material Figure 1. Gridding system on sheet after being formed. X1 32.8077 32.5823 0.0680 0.0540 sag stretching was eliminated. When a material is run X2 32.7825 32.5545 0.0604 0.0547 The mold was first set on the lower platen (shown in a thermoforming machine with the mold set on the Z 3.6531 3.5861 0.1874 0.0854 Thickness Average Average St. Dev. St. Dev. in Figure 2) of the MAAC Thermoformer that was bottom platen, the sag of the material as it comes out of Front 0.0728 0.0640 0.0066 0.0063 used on the project. The first set of parts that were the oven is met by the mold coming up into the pliable Right 0.0699 0.0541 0.0072 0.0036 made on the machine was to try and help set up a sheet and going through it to help create a seal to be Back 0.0693 0.0590 0.0086 0.0056
process that would produce a quality part, so that a able to vacuum the sheet around the dimensions of the Left 0.0733 0.0536 0.0105 0.0034 BL 8(Y1) 7(Y2) 6(Y3) Top 0.1280 0.1207 0.0068 0.0037 production-style run could be started. After a few mold. This phenomenon stretches the material twice, parts were formed, it was easily determined that the which 9 (X2) could lessenMD some of the material’s5 (X2) important mold should be hung from the top platen rather than physical properties. If the properties are compromised, the bottom platen. the part10 (X1) has a possibility ofTD failing once4 (X1)it gets out to its customer and starts being used. Hanging the mold 1
from theFL top 1(Y1)platen eliminates2(Y2) this3(Y3) from happening to the material. With the mold coming from the top of Circulator I.R. Eye theRun sagging Coolingmaterial, Time there is only one stretch on the material, which is in the sameTem directionp ofTem thep sag, and 1 - -- then the vacuum created by the seal between material 2 - -+ and3 moldBL sucks 8(Y1) the- material 7(Y2) back +- 6(Y3) to the shape of the mold.4 This type of- molding minimizes ++ the stress on the 9 (X2) MD 5 (X2) material5 and theoretically+ eliminates -- the extra physical property6 damage +done by double +- stretching with molds set on710 the(X1) bottom+ platen. TD -+4 (X1) 8After the urethane+ mold was ++ hung from the top 2(Y2) platen, theFL machine 1(Y1) settings were3(Y3) altered so that they
Figure 2. Renshape mold on bottom platen. were the exact same as the bottomCirculator platen I.R. settings Eye and RunREN Cooling2 mins Time 72 hrs 2 mins 72 hrs itDimensions was time again Average to try Average and findTem St. the Dev.p correct St.Tem Dev. settingsp and The mold was switched from being set on the cycle1Y1 to produce 15.2772 quality- 14.7679 parts repeatedly. 0.0737 -- Once 0.0817 they were
bottom platen to being hung from the top platen, found,2Y2 a production-style 15.2703- 14.6292 run could 0.0916 -+ be performed. 0.1319 Y3 15.2146 14.6189 0.1027 0.1786 3 - +- 22 Thermoforming quarterly X1 32.8077 32.5823 0.0680 0.0540 4X2 32.7825- 32.5545 0.0604 ++ 0.0547 5Z 3.6531+ 3.5861 0.1874 -- 0.0854 Thickness6 Average+ Average St. +- Dev. St. Dev. Front 0.0728 0.0640 0.0066 0.0063 1TFQ 2ND Qtr 11 ins.indd 22 7 + -+9/12/11 11:33:23 AM Right 0.0699 0.0541 0.0072 0.0036 8 + ++ Back 0.0693 0.0590 0.0086 0.0056 Left 0.0733 0.0536 0.0105 0.0034
Top 0.1280 0.1207 0.0068 0.0037 REN 2 mins 72 hrs 2 mins 72 hrs Dimensions Average Average St. Dev. St. Dev. Y1 15.2772 14.7679 0.0737 0.0817 Y2 15.2703 14.6292 0.0916 0.1319 Y3 15.2146 14.6189 0.1027 0.1786 X1 32.8077 32.5823 0.0680 0.0540 1 X2 32.7825 32.5545 0.0604 0.0547 Z 3.6531 3.5861 0.1874 0.0854 Thickness Average Average St. Dev. St. Dev. Front 0.0728 0.0640 0.0066 0.0063 Right 0.0699 0.0541 0.0072 0.0036 Back 0.0693 0.0590 0.0086 0.0056 Left 0.0733 0.0536 0.0105 0.0034 Top 0.1280 0.1207 0.0068 0.0037
1
A few problems were run into when trying to find calipers set at the edge of the jig and being extended the “perfect” cycle. The first problem was that the rails into the formed sheet. that hold the sheet in place were set too close to the mold and the mold was going too far through the rails. This caused the back of the sheet to rip out completely. After this, the rails were moved out to about one-half inch from the mold and the mold was programmed so that it didn’t go through the rails as far. The top of the mold was then set to go down 5.5 inches from the sheet in the rails. The sheet didn’t rip completely when the mold came down through it, but it did leave a few small tear spots, which were a sign of the side of the sheet BL 8(Y1) 7(Y2) 6(Y3) closest to the oven being too hot when it came out to be 9 (X2) MD 5 (X2) formed (shown in Figure 4). This problem was fixed by lowering the oven percentages in the back of the oven TD so that part of the sheet wouldn’t be as hot as it exited Figure10 (X1) 5. HDPE sheet in aluminum jig. 4 (X1) the oven. After the cycle was finalized, the production- BL 8(Y1) 7(Y2) 6(Y3) AlsoFL shown 1(Y1) in Figure2(Y2) 5 3(Y3) is how thickness style run was ready to be started. A production-style measurements9 (X2) were takenMD on each of the sheets5 (X2) after run is basically just a certain number of sheets run one Circulator I.R. Eye theyRun had been Cooling measured Time using the jig. A drill and hole right after another. This production run was set for 10 Temp Temp saw attachment were used to cutTD one-inch holes in 1 10 (X1) - --4 (X1) sheets, and there were a number of variables that were the top, front, left, back, and right sides of the sheet. 2 - -+ measured related to the machine during the production The discs thatFL were 1(Y1) produced2(Y2) were then3(Y3) measured for 3 - +- run. They were: temperature of the front of the mold, thickness.4 Figure- 5 also shows ++ that the holes were the top of the mold, and the back of the mold (all of Circulator I.R. Eye drilled5 Run in the left Cooling +side of Time each side -- immediately after which were taken right before the next sheet in the run the sheet was taken out of the machine.Temp MeasurementsTemp 6 1 +- +- -- was loaded in the rails), sheet temperature as it came taken7 24 or more+ hours later were -+ drilled out of the out of the oven right before forming, and temperature 2 - -+ right8 side of each+ side. ++ of the sheet after the rails opened after cooling and the 3 - +- Also4 shown in - Figure 5 is ++how the height formed part was ready to be taken out of the machine. measurement5 was taken+ for each part -- after the 10 jig Room temperature and humidity were also measured REN 2 mins 72 hrs 2 mins 72 hrs measurements6 were + taken. Two aluminum +- blocks before every sheet was loaded. Dimensions Average Average St. Dev. St. Dev. wereY1 placed7 15.2772on the long+ 14.7679 sides of 0.0737 the -+ aluminum 0.0817 jig,
and Y2an aluminum8 15.2703 meter+ 14.6292 stick was 0.0916 placed ++ on 0.1319 top of the blocks. Y3 The dial 15.2146 calipers 14.6189 were then 0.1027 extended 0.1786 from the X1 32.8077 32.5823 0.0680 0.0540 top of the meter stick to the top of the formed sheet. X2REN 32.78252 mins 32.5545 72 hrs 0.0604 2 mins 0.0547 72 hrs ThatZDimensions number was 3.6531 Average then plugged 3.5861 Average into 0.1874 a St. formula Dev. 0.0854 St.(5.5625 Dev. Thickness Average Average St. Dev. St. Dev. – x = height)Y1 to obtain 15.2772 the 14.7679 actual height 0.0737 of the 0.0817 part. Front 0.0728 0.0640 0.0066 0.0063 Y2 15.2703 14.6292 0.0916 0.1319 TheRight number 0.0699 5.5625 comes 0.0541 from 0.0072 the jig 0.0036 thickness, Y3 15.2146 14.6189 0.1027 0.1786 Back 0.0693 0.0590 0.0086 0.0056 aluminumX1 block height, 32.8077 and 32.5823 meter stick 0.0680 height. 0.0540 Left 0.0733 0.0536 0.0105 0.0034 AfterX2 all of the 32.7825 measurements 32.5545 were0.0604 taken, 0.0547 they Top 0.1280 0.1207 0.0068 0.0037 could beZ plugged 3.6531 into formulas 3.5861 that0.1874 would 0.0854 give Figure 4. Tears in back of formed sheet. Thickness Average Average St. Dev. St. Dev. Front 0.0728 0.0640 0.0066 0.0063 BL 8(Y1) 7(Y2) 6(Y3) After the formed sheet came out of the mold, it Right 0.0699 0.0541 0.0072 0.0036 Back 0.0693 0.0590 0.0086 0.0056 was set into the measuring jig that was made for the 9 (X2) MD 5 (X2) Left 0.0733 0.0536 0.0105 0.00341 dimensions of what the sheet should be as it comes Top 0.1280 0.1207 0.0068 0.0037 off the mold. The aluminum jig (shown in Figure 5) is 10 (X1) TD 4 (X1) 33.500 inches wide and 15.875 inches long. The sheet was placed in the jig the exact same way every time, FL 1(Y1) 2(Y2) 3(Y3) and measured in 10 different places along the lengths Figure 6. Measurement points and formula labels. Circulator I.R. Eye 1 and widths of the part (shown in Figure 6) using dial Run Cooling Time (continued on next page) Temp Temp 1 Thermoforming- -- QUARTERLY 23 2 - -+ 3 - +- 4 - ++ 1TFQ 2ND Qtr 11 ins.indd 23 9/12/11 11:33:27 AM 5 + -- 6 + +- 7 + -+ 8 + ++
REN 2 mins 72 hrs 2 mins 72 hrs Dimensions Average Average St. Dev. St. Dev. Y1 15.2772 14.7679 0.0737 0.0817 Y2 15.2703 14.6292 0.0916 0.1319 Y3 15.2146 14.6189 0.1027 0.1786 X1 32.8077 32.5823 0.0680 0.0540 X2 32.7825 32.5545 0.0604 0.0547 Z 3.6531 3.5861 0.1874 0.0854 Thickness Average Average St. Dev. St. Dev. Front 0.0728 0.0640 0.0066 0.0063 Right 0.0699 0.0541 0.0072 0.0036 Back 0.0693 0.0590 0.0086 0.0056 Left 0.0733 0.0536 0.0105 0.0034 Top 0.1280 0.1207 0.0068 0.0037
1
BL 8(Y1) 7(Y2) 6(Y3)
9 (X2) MD 5 (X2)
the formed sheet lengths and widths at the given were 205 and 170 degrees Fahrenheit, respectively, and 10 (X1) TD 4 (X1) measurement points. The original measurement points the high and low values for I.R. eye temperature were and their corresponding formula labels are shown in 330 and 400FL degrees 1(Y1) Fahrenheit,2(Y2) respectively.3(Y3) Figure 6. Circulator I.R. Eye The formulas were calculated by taking the Run Cooling Time original jig Y (machine) direction (15.875 inches) Temp Temp 1 - -- or the original jig X (transverse) direction (33.500 2 - -+ inches) and subtracting the two measurement points 3 - +- that go together (1-8, 3-6, 5-9, etc.). An example for 4 - ++ the Y1 measurement would be 15.875 inches minus 5 + -- the combination of measurements 1 and 8 (0.1025 6 + +- and 0.4865), measured with the dial calipers, which 7 + -+ 8 + ++ would equal out to a Y1 length of 15.2860 inches. The caliper measurements help show the warpage of Figure 7. DOE Table. the formed part and the formulas for the length and RENResults2 mins and 72 hrsDiscussion 2 mins 72 hrs width help show the overall shrinkage. Dimensions Average Average St. Dev. St. Dev. After the production style run was completed with Y1 15.2772 14.7679 0.0737 0.0817 The first results that were obtained were from the the Renshape urethane mold, the aluminum mold production-styleY2 15.2703 run of the14.6292 Renshape 0.0916 (REN) 0.1319 mold. Y3 15.2146 14.6189 0.1027 0.1786 needed to be prepared so that it too could be hung When theX1 machine 32.8077 was first 32.5823 heated 0.0680 up, five 0.0540 parts were in the machine and used for a production-style run run to solidifyX2BL the 32.78258(Y1) cycle so 32.5545 7(Y2) there wouldn’t 0.0604 6(Y3) be 0.0547 a lot of to compare with the production run performed with variationZ during the 3.6531 production 3.5861 run. 0.1874Since the 0.0854 five parts Thickness9 (X2) AverageMD Average St. Dev.5 St. (X2) Dev. the Renshape mold. The aluminum mold was sealed were ran,Front the mold 0.0728 already started 0.0640 to heat 0.0066 up. Appendix 0.0063 A and then was switched out with the Renshape mold shows Rightthe temperatures 0.0699 measured 0.0541 during 0.0072 the production 0.0036 so that a production-style run could be performed. style run.Back10 (X1)The graph 0.0693 shows 0.0590 thatTD every 0.0086 measured4 0.0056(X1) mold Left 0.0733 0.0536 0.0105 0.0034 The aluminum mold has water lines inside of it, so temperature increased by at least 10 percent and up to TopFL 1(Y1) 0.1280 0.12072(Y2) 0.00683(Y3) 0.0037 25 percent, and the forming temperature increased by a circulator was used to send hot water into the mold to control the temperature of the sheets, so that there 6 percent without any parametersCirculator being changed.I.R. Eye The Run Cooling Time wouldn’t be an increase in mold temperature as there ejection temperature also increasedTem byp 12 percentTemp in 7 was in the Renshape production run. All of the same runs until1 cooling time- was increased -- to help make the 1 measurements were performed during the aluminum parts easier2 to handle- out of the mold. -+
production-style run, with the only additions being The3 measurements- that were taken +- on the REN mold the circulator temperature and the inlet and outlet parts right4 after forming- and 72 hours ++ after forming are temperatures to and from the mold and circulator. shown 5in Figure 8. The+ most noticeable -- thing about the 6 + +- A Design of Experiment (DOE) was also REN mold measurements was how much the part shrank in only 7three days. The+ length of the formed -+ sheet shrank performed for the project using the temperature- 8 + ++ about one-half inch in three days and the width shrank controlled aluminum mold. The main purpose of the DOE was to show if extreme high and low values were mixed and used in a cycle could produce quality parts REN 2 mins 72 hrs 2 mins 72 hrs like the production-style run. The three factors used Dimensions Average Average St. Dev. St. Dev. Y1 15.2772 14.7679 0.0737 0.0817 in the DOE were cooling time, circulator temperature, Y2 15.2703 14.6292 0.0916 0.1319 and infrared (I.R.) eye temperature. The infrared eye Y3 15.2146 14.6189 0.1027 0.1786 is a laser that measures the temperature of the sheet in X1 32.8077 32.5823 0.0680 0.0540 X2 32.7825 32.5545 0.0604 0.0547 the oven. Figure 7 shows all the different set-ups ran Z 3.6531 3.5861 0.1874 0.0854 for the DOE. The MAAC thermoforming machine Thickness Average Average St. Dev. St. Dev. allows for either a time or temperature-based oven Front 0.0728 0.0640 0.0066 0.0063 Right 0.0699 0.0541 0.0072 0.0036 time. The cycle that was used in this project was Back 0.0693 0.0590 0.0086 0.0056 temperature-based. The high and low values for Left 0.0733 0.0536 0.0105 0.0034 cooling time were 150 and 90 seconds, respectively. Top 0.1280 0.1207 0.0068 0.0037
The high and low values for circulator temperature Figure 8. REN mold measurements. 24 Thermoforming quarterly 1
1TFQ 2ND Qtr 11 ins.indd 24 9/12/11 11:33:30 AM about one-quarter inch in three days. The standard basically stayed the same overall, but have a slight deviation of the length averages about 80 thousandths upwards undulation in the middle of the run. of an inch and the width’s standard deviation averages Appendix C-2 shows the part widths after 72 hours 64 thousandths of an inch. The height shrank about one- over the course of the production run. The REN mold sixteenth of an inch in three days. part widths both have downward sloping trends, while The thickness of the sheet also shrank dramatically the temperature-controlled aluminum mold part widths after three days. The front thickness shrank about 12 have one upward and one slightly downward sloping percent, the right shrank 23 percent, the back shrank 15 trend. This shows that even though the aluminum has percent, the left shrank 27 percent, and the top shrank differing trends, it is still closer to staying the same 6 percent. The standard deviation for the thicknesses than the REN mold part widths. averages around 8 thousandths of an inch right after The measurements of the formed sheets (shown forming, but only around 5 thousandths of an inch after in Figure 9) showed much better results than the 72 hours. This shows that the thicknesses vary a lot REN mold. While the REN mold widths shrank an right off of the mold, but get to a more stable state after average of one-half inch in 3days, the aluminum mold they shrink. widths only shrank about one-tenth of an inch. The After all of the data was collected and measured for REN mold and aluminum mold lengths both shrank the urethane mold, the temperature-controlled aluminum about one-quarter inch. The REN mold height shrank mold was ready to be switched out. Appendix B shows about one-sixteenth of an inch and the aluminum mold the forming temperatures during the production-style shrank less than one-thirty second. run using the aluminum mold. This mold required a Aluminum Al 2 mins Al 72 hrs Al 2 mins Al 72 hrs few more measurements: rail temperature, circulator Dimensions Average Average St. Dev. St. Dev. temperature, and inlet and outlet temperature of the Y1 15.1864 15.0772 0.0532 0.0629 circulator. Y2 15.3429 15.2224 0.0556 0.0498 The production-style run was started with a 100 Y3 15.2405 15.1412 0.0387 0.0494 X1 32.7307 32.4864 0.0815 0.0799 second cooling time and a 370 degree Fahrenheit X2 32.6969 32.5176 0.0234 0.0627 I.R. eye. Before sheet 4 was loaded, the cooling time Z 3.5513 3.5266 0.0566 0.0451 was extended to 120 seconds, because the sheet was Thickness Average Average St. Dev. St. Dev. Front 0.0939 0.0903 0.0021 0.0047 consistently coming out at around 200 degrees. It came Right 0.0838 0.0807 0.0064 0.0054 down to about 190 degrees, and then before sheet 5 was Back 0.0846 0.0918 0.0028 0.0055 loaded, the cooling was increased to 150 seconds and Left 0.0810 0.0835 0.0021 0.0044 Top 0.1029 0.1083 0.0017 0.0055 the I.R. eye was changed to 360 degrees Fahrenheit, Figure 9. Aluminum mold measurements. because at 370 degrees the sheet was coming out in a consistent pattern of 343 and 330 degrees Fahrenheit. The aluminumOVERALL thicknesses SHRINKAGE only changed at most Before sheets 7, 8, and 9 were loaded, the cooling time 8.5 percent,REN and averaged72 hrs aboutAluminum 3.5 percent,72 hrs while the was decreased to 130 seconds, 120 seconds, and 110 REN moldWidth thicknesses 3.816% changed Width up to 27 0.719% percent and Length 0.691% Length 0.647% seconds respectively to see what kind of effect it would averaged 16.5 percent. Height 1.836% Height 0.696% have on the ejection temperature. This can also be seen Figure 10 (shown on the next page) shows the in Appendix B. As seen on Appendix B, the top of the overall shrinkage percentages for the REN and mold barely changed at all during the production run, aluminumWarpage mold.REN The 72hrs REN Al 72hrs mold RENwidths 72hrs shrank Al 72hrs over
while the front and back of the mold increased slightly, 5 Measurementtimes more Pt. thanAverage the aluminum, Average St.the Dev. lengths St. Dev.shrank 1 0.2195 0.2134 0.0551 0.0687 with the back increasing the most, because it is closest only one-half2 percent 0.2342 more, 0.1188 and the 0.0719 heights 0.0131 shrank to the oven (which reaches upwards of 700 degrees over 3 times3 more 0.2000 than the 0.1339 aluminum. 0.0481 0.0192 Fahrenheit). The rails, circulator, and inlet and outlet Warpage4 was 0.2427 also a key 0.1639 factor 0.0281in the REN 0.0686 mold parts after5 72 hours 0.2485 (shown 0.1583 in Figure 0.0394 11 on 0.0278the next temperatures all stayed virtually the same throughout 6 1.0562 0.5999 0.1765 0.0538 the production run. page). These7 measurements 1.0117 0.5339 come 0.1038 directly from0.0514 the Appendix C-1 shows the part lengths after 72 hours aluminum8 jig, and 0.8877 show the 0.5845 difference 0.0681 from 0.0609the edge 9 0.6971 0.8242 0.0510 0.0454 over the course of the production run. The REN mold of the jig to the edge of the part. Each formed sheet 10 0.6751 0.8498 0.0659 0.0605 parts have a downward sloping trend for the lengths. that was brought off of the thermoformer and placed The temperature-controlled aluminum mold parts (continued on next page)
Thermoforming QUARTERLY 25
1TFQ 2ND Qtr 11 ins.indd 25 9/12/11 11:33:32 AM
2
Aluminum Al 2 mins Al 72 hrs Al 2 mins Al 72 hrs DimensionsAluminum Al Average 2 mins Al Average 72 hrs Al St. 2 Dev. mins Al St. 72 Dev. hrs DimensionsY1 Average 15.1864 Average 15.0772 St. 0.0532 Dev. St. 0.0629 Dev. Y2Y1 15.342915.1864 15.222415.0772 0.05560.0532 0.04980.0629 Y3Y2 15.240515.3429 15.141215.2224 0.03870.0556 0.04940.0498 X1Y3 32.730715.2405 32.486415.1412 0.03870.0815 0.04940.0799 X2X1 32.696932.7307 32.517632.4864 0.02340.0815 0.06270.0799 X2Z 32.6969 3.5513 32.5176 3.5266 0.02340.0566 0.06270.0451 ThicknessZ Average 3.5513 Average 3.5266 St. 0.0566 Dev. St. 0.0451 Dev. ThicknessFront Average 0.0939 Average 0.0903 St. 0.0021 Dev. St. 0.0047 Dev. RightFront 0.08380.0939 0.08070.0903 0.00640.0021 0.00540.0047 BackRight 0.08460.0838 0.09180.0807 0.00280.0064 0.00550.0054 Back 0.0846 0.0918 0.0028 0.0055 Left 0.0810 0.0835 0.0021 0.0044 Left 0.0810 0.0835 0.0021 0.0044 Top 0.1029 0.1083 0.0017 0.0055 Top 0.1029 0.1083 0.0017 0.0055
OVERALL SHRINKAGE The grid that was placed on the bottom of the sheets REN OVERALL72 hrs SHRINKAGEAluminum 72 hrs was to show stretching in the machine and transverse WidthREN 3.816%72 hrs Aluminum Width 0.719%72 hrs direction. The grid on the Renshape mold expanded an Width 3.816% Width 0.719% Length 0.691% Length 0.647% average of 10 thousandths of an inch on the top of the LengthHeight 1.836%0.691% LengthHeight 0.696%0.647% FigureHeight 10. Overall 1.836% Shrinkage. Height 0.696% mold in the machine direction and shrank an average of 20 thousandths in the transverse direction. On the drawn
Warpage REN 72hrs Al 72hrs REN 72hrs Al 72hrs part of the sheet, the material expanded an average MeasurementWarpage Pt. RENAverage 72hrs AverageAl 72hrs REN St. Dev. 72hrs Al St. 72hrsDev. Measurement1 Pt. Average 0.2195 Average 0.2134 St. 0.0551 Dev. St. 0.0687 Dev. of 1.500 inches over the original inch in the machine 21 0.23420.2195 0.11880.2134 0.07190.0551 0.01310.0687 direction and shrank an average of 25 thousandths in 32 0.20000.2342 0.13390.1188 0.04810.0719 0.01920.0131 the transverse direction. The aluminum mold expanded 43 0.24270.2000 0.16390.1339 0.02810.0481 0.06860.0192 54 0.24850.2427 0.15830.1639 0.03940.0281 0.02780.0686 an average of 100 thousandths in the machine direction 65 1.05620.2485 0.59990.1583 0.17650.0394 0.05380.0278 and 120 thousandths in the transverse direction on the 76 1.01171.0562 0.53390.5999 0.10380.1765 0.05140.0538 top of the part. On the drawn section of the part, the 87 0.88771.0117 0.58450.5339 0.06810.1038 0.06090.0514 98 0.69710.8877 0.82420.5845 0.05100.0681 0.04540.0609 material expanded an additional inch in the machine 109 0.67510.6971 0.84980.8242 0.06590.0510 0.06050.0454 direction and shrank an average of 20 thousandths in 10 0.6751 0.8498 0.0659 0.0605 the transverse direction. All grid measurements were Figure 11. Warpage measurements. taken after 72 hours. These measurements show that the in the jig was pushed in the bottom right hand corner temperature-controlled aluminum mold parts held their (in between measurement point 3 and 4 as seen in dimensions a lot more than the Renshape mold parts, Figure 6. Points 1, 2, and 3 made up the front of the as the Renshape mold parts stretched and then shrank part. The REN mold seems to be better on the front back down below the original grid measurements after as it only changed about 34 thousandths while the 72 hours. aluminum changed 100 thousandths from point 1 to 2, The Design of Experiment results showed that only a but that is the only instance of the REN being slightly couple parts off of the aluminum temperature-controlled better than the aluminum. Points 4 and 5 make up the mold would be deemed quality. Run 1 with all the low right side of the part, and the warpage was about six settings, Run 3 with just a high circulator temperature, thousandths for both the REN and aluminum mold. Run 5 especially with just a high cooling time, and Run The back is where the REN mold really warped. 6 with high cooling time and circulator temperature, all It varied about 75 thousandths where the aluminum produced a part that was too cold when it was ejected. mold only varied about 65 thousandths. The left The top of the part stuck to the top of the mold, and sides of the parts both varied about 20 thousandths. permanently deformed the part by stretching it (shown in Figure 1). Run 2 with just a high I.R. eye temperature The standard deviation for the REN mold show how 2 much the warpage varied on any one part. The front and Run 7 with a high I.R. eye and high cooling2 time, varied an average of 60 thousandths on the REN mold produced full parts that ended up with a lot of warpage. and only about 40 thousandths on the aluminum. The Run 4 with a high circulator temperature and high I.R. right sides were about the same, with the aluminum eye temperature produced a full part that only exhibited having a slightly higher standard deviation. The back a small amount of warpage, and Run 8, which had all of the REN mold parts varied an average of 110 high settings, produced the best part of the DOE. This thousandths of an inch, while the aluminum only shows that the cycle that was set up for the production varied an average of 53 thousandths of an inch. The run is the best for this material. left sides of the REN mold parts varied an average of Tensile tests were run on a number of the parts, with 58 thousandths, while the aluminum only varied an samples being cut out of the front, back, left, and right average of 52 thousandths. All these averages show portions of the formed sheet. The results are shown in that the REN mold was much more unpredictable Appendix D. Unfortunately, the data that was collected when it was measured in the jig, because every part from the temperature-controlled aluminum tool parts shrank and warped differently, while the aluminum was too random to determine whether one mold produced mold was much more consistent. tougher parts than the other. Overall, the results look
26 Thermoforming quarterly
1TFQ 2ND Qtr 11 ins.indd 26 9/12/11 11:33:36 AM similar. The yield and maximum stresses, yield and 2. Harper, Charles A. Handbook of Plastic maximum elongation percentages, and maximum energy Processes. Hoboken, NJ: Wiley-Interscience, were all similar. The modulus measurements from the 2006. Print. parts of the temperature-controlled aluminum mold I3. llig, Adolf, and Peter Schwarzmann. were very random and ranged from 3410 to 1.2 million, Thermoforming: A Practical Guide. Munich: so it was deemed irrelevant for the comparison. Hanser, 2001. Print. 4. Peacock, Andrew J. Handbook of Polyethylene: Conclusion Structures, Properties, and Applications. New Overall, the temperature-controlled aluminum York: Marcel Dekker, 2000. Print. mold showed a much more consistent process than the 5. “Sheet/Thermoforming Grade HDPE.” www. Renshape mold did. It shrank less, warped less, and matweb.com. Material Property Data. Web. had a much higher dimensional stability. With that,
Appendices A: Renshape Forming Temperatures 340 Mold Front 320 300 Mold Back 280 Mold Top 260 240 Ejection Temp 220 Forming Temp
Temperature (°F) Temperature 200 Linear (Mold Front) 180 160 Linear (Mold Back) 12345678910 Linear (Mold Top) Part Number Linear (Ejection Temp)
(continued on next page)
B: Aluminum Forming TemperaturesThermoforming QUARTERLY 27 350
1TFQ 2ND Qtr 11 ins.indd 27 Mold Front 9/12/11 11:33:37 AM 300 Mold Back
250 Mold Top Sheet at Molding 200 Sheet at Demolding
Temperature (°F) Temperature 150 Rails Circulator 100 12345678910 Inlet Temp Outlet Temp Part Number
3
A: Renshape Forming Temperatures 340 Mold Front 320 300 Mold Back 280 Mold Top 260 240 Ejection Temp 220 Forming Temp
Temperature (°F) Temperature 200 Linear (Mold Front) 180 160 Linear (Mold Back) 12345678910 Linear (Mold Top) Part Number Linear (Ejection Temp)
B: Aluminum Forming Temperatures 350 Mold Front 300 Mold Back
250 Mold Top Sheet at Molding 200 Sheet at Demolding
Temperature (°F) Temperature 150 Rails Circulator 100 12345678910 Inlet Temp Outlet Temp Part Number
C-1:C-1: 72hr72hr PartPart LengthLength 15.4 15.4 15.2 15.2 15.0 REN Y1 15.0 REN Y1 REN Y2 14.8 REN Y2 14.8 REN Y3 14.6 REN Y3 Part WidthPart (in) 14.6 Al Y1 Part WidthPart (in) 14.4 Al Y1 14.4 Al Y2 14.2 Al Y2 14.2 Al Y3 12345678910 Al Y3 12345678910 3 Part Number Part Number
C-2:C-2: 72hr72hr PartPart WidthWidth
32.675 32.675 REN X1 32.625 REN X1 32.625 REN X2 32.575 REN X2 32.575 Al X1 32.525 Al X1 32.525 Al X2 32.475 Al X2 Part LengthPart (in) 32.475 Linear (REN X1) Part LengthPart (in) 32.425 Linear (REN X1) 32.425 Linear (REN X2) 32.375 Linear (REN X2) 32.375 Linear (Al X1) 12345678910 Linear (Al X1) 12345678910 Linear (Al X2) Part Number Linear (Al X2) Part Number
D: TENSILE TESTING Type Yield Stress (psi) Max Stress (psi) Yield Elongation (%)D: BreakTENSILE Stress (psi)TESTING Modulus (psi) Max Energy (in*lb/in3) Max Elongation (%) TE Auto (%) 3 RENType front Yield 2830.00Stress (psi) Max 2830.00Stress (psi) Yield Elongation14.23 (%) Break1157.23 Stress (psi) Modulus 53133.33 (psi) Max Energy275.33 (in*lb/in ) Max Elongation13.79 (%) TE Auto664.00 (%) 28 TRENhermoformingAl front 2830.00 2610.00 qua 2830.00 2610.00rterly 14.2313.74 1157.23760.50 53133.33 514600.00 275.33276.50 13.7913.47 664.00270.60 Al front 2610.00 2610.00 13.74 760.50 514600.00 276.50 13.47 270.60 REN back 2860.00 2860.00 13.72 1142.50 65250.00 278.75 12.88 486.25 RENAl backback 2860.00 3086.67 2860.00 3086.67 13.7214.78 1142.50806.20 65250.00 456900.00 278.75351.67 12.8814.40 486.25249.33 Al back 3086.67 3086.67 14.78 806.20 456900.00 351.67 14.40 249.33 1TFQ 2ND Qtr 11 ins.indd 28 9/12/11 11:33:40 AM REN left 2835.00 2835.00 12.82 2169.67 42125.00 310.25 15.69 853.00 RENAl leftleft 2835.00 1809.67 2835.00 1813.33 12.8217.89 2169.67899.33 42125.00 19570.00 310.25198.00 15.6916.83 853.001040.67 Al left 1809.67 1813.33 17.89 899.33 19570.00 198.00 16.83 1040.67 REN right 2765.00 2765.00 16.06 2109.25 31950.00 283.00 15.53 1032.50 RENAl right 2765.00 2776.67 2765.00 2783.33 16.0617.43 2109.252032.33 31950.00 131100.00 283.00313.67 15.5316.73 1032.501039.00 Al right 2776.67 2783.33 17.43 2032.33 131100.00 313.67 16.73 1039.00
4 4
C-1: 72hr Part Length 15.4
15.2
15.0 REN Y1 REN Y2 14.8 REN Y3 14.6 Part WidthPart (in) Al Y1 14.4 Al Y2 14.2 Al Y3 1 2 3 4 5 6 7 8 910
Part Number
C-2: 72hr Part Width
32.675 REN X1 32.625 REN X2 32.575 Al X1 32.525 Al X2 32.475 Part LengthPart (in) Linear (REN X1) 32.425 Linear (REN X2) Thermoforming32.375 High Density Polyethylene Sheet Using Linear (Al X1) Temperature-Controlled12345678910 Aluminum Tooling (continued) Linear (Al X2) AppendicesPart Number (continued)
D: TENSILE TESTING Type Yield Stress (psi) Max Stress (psi) Yield Elongation (%) Break Stress (psi) Modulus (psi) Max Energy (in*lb/in3) Max Elongation (%) TE Auto (%) REN front 2830.00 2830.00 14.23 1157.23 53133.33 275.33 13.79 664.00 Al front 2610.00 2610.00 13.74 760.50 514600.00 276.50 13.47 270.60
REN back 2860.00 2860.00 13.72 1142.50 65250.00 278.75 12.88 486.25 Al back 3086.67 3086.67 14.78 806.20 456900.00 351.67 14.40 249.33
REN left 2835.00 2835.00 12.82 2169.67 42125.00 310.25 15.69 853.00 Al left 1809.67 1813.33 17.89 899.33 19570.00 198.00 16.83 1040.67
REN right 2765.00 2765.00 16.06 2109.25 31950.00 283.00 15.53 1032.50 Al right 2776.67 2783.33 17.43 2032.33 131100.00 313.67 16.73 1039.00
REDUCE! 4 REUSE! RECYCLE!
REDUCE! REUSE! RECYCLE!
Thermoforming QUARTERLY 29
1TFQ 2ND Qtr 11 ins.indd 29 9/12/11 11:33:43 AM Thermoforming Thermoforming and Sustainability Quarterly® Placon Opens “We are excited about our new approximately 12,000 BTUs of $14 Million EcoStar facility as it enables us energy. Recycling Facility to produce consumer packaging from 100% post-consumer PET The new facility has created for Post-Consumer recyclate,” said the company CEO 44 new jobs. Currently, Placon Bottles and Dan Mohs. employs more than 400 people Thermoforms worldwide. x Along with the ability to wash EcoStar - Recycle, and recycle PET, half of the new Replastic, Results facility is engineered for sheet Claiming FITCHBURG, WI (May 4, extrusion. This operational layout Recyclability: Tips 2011) – Placon Corporation, a eliminates non-value-added and Tricks for the thermoformer and plastic sheet activities and reduces the total Unwary extruder, announces the opening carbon footprint by bringing the of its EcoStar® closed-loop material supply chain closer to By Sheila A. Millar, Partner sheet production. Moreover, the J. C. Walker, Partner recycling facility. Keller and Heckman LLC supply of post-consumer plastics Placon becomes one of the processed by the facility are n a much anticipated action, first thermoforming companies collected primarily in the Midwest, Ithe Federal Trade Commission in the food and consumer streamlining local and regional (“FTC” or “Commission”), packaging industry to implement operations at every step of the released proposed revisions its own in-house recycling to process. to its Guides for the Use of process post-consumer bottles Environmental Marketing Claims as well as thermoforms. With “Our $14 million investment (16 C.F.R. Part 260) (“Guides”) this new 70,000 square foot demonstrates our commitment last fall, soliciting additional facility, Placon accomplishes to sustainable packaging and public comments on the changes its plan to create a standalone the reduction of solid waste. which will be evaluated before manufacturing location with its We believe that the best way to finalizing the updated Guides. In own brand identity under the reduce energy consumption and preparing for these revisions, the EcoStar name. conserve resources, from a cradle- FTC conducted several workshops, to-grave perspective, is to recycle sponsored consumer research, EcoStar purchases bales of plastic packaging back into plastic and reviewed extensive public curbside collected post-consumer packaging, thereby closing the comments submitted through PET bottles and mixed bales loop,” Mohs said. several different proceedings of post-consumer thermoform to identify emerging issues packaging, grinds them, washes For nearly two decades, Placon has in environmental claims. The them, and processes them into pioneered the use of post-consumer proposed Guides offer guidance sheet and flake. EcoStar recycled recycled polyethylene terephthalate (sometimes limited) on new terms, PET products include flake, (RPET) in the consumer packaging including “renewable,” “renewable LNO (letter of non-object) industry. In the past seven years energy” and “carbon offset” claims. flake for food packaging, and alone, it has diverted more than The revisions, however, do not sheet products for the food and one billion discarded bottles provide guidance for the increasing consumer products markets. At from landfills. According to the claims of “sustainability,” full capacity, EcoStar will process Environmental Protection Agency, “organic,” or “natural.” Guidance 36 million pounds of inbound recycling one pound of PET instead on terms already covered was material. of using virgin material saves largely left unchanged.
30 Thermoforming quarterly
1TFQ 2ND Qtr 11 ins.indd 30 9/12/11 11:33:44 AM The proposed Guides reflect the The Commission’s proposed as recycled content must have FTC’s current thinking on the 60% threshold received mixed actually been diverted from the adequacy of certain claims, the review, with some in support, solid waste stream, either during need for qualification, and the some suggesting it should be the manufacturing process (pre- amount of substantiation needed lowered, some urging adoption consumer) or after consumer use to support such claims. Notably, of the International Standards (post-consumer). the proposed Guides provide Organization’s “reasonable clarification on the Commission’s proportion” standard, and one The proposed Guides do address current approach to recyclable and suggesting higher thresholds for suggestions about expanding recycled content claims. each of the three levels. Most who the definition of post-consumer support quantifying a “significant material to include the ISO percentage” generally suggested 14021 approach. In declining Recyclable Claims 20% or 30% as the standard, but to adopt such an approach, Claims for recyclability most suggested that the FTC avoid the FTC noted that under ISO and recycled content are a percentage reference. 14021, material returned from addressed in both the current the distribution chain (e.g., and proposed Guides. Despite A longstanding criticism of the overstock) would qualify as criticism of the FTC’s approach FTC’s approach is the rather post-consumer recycled material. to recyclable claims from consumer-unfriendly qualifiers Because this material never organizations seeking greater that it recommends. The FTC actually reaches the consumer, it international harmonization, continues to maintain that, is unlikely that consumers would the FTC maintained its three- standing alone, “recyclable interpret such material as “post- tiered distinction for qualifying where facilities exist,” “check consumer.” recyclable claims depending on to see if recycling facilities whether a “substantial majority,” exist in your area” and “please Further, the FTC declined to a “significant percentage,” or recycle” do not adequately qualify prohibit pre-consumer recycled fewer consumers or communities recyclable claims. In essence, content claims, as suggested by have access to recycling facilities. these statements are treated as some workshop commenters, noting that this information may To make an unqualified claim unqualified claims which the FTC will view to be misleading be important to consumers. At about recyclability, recycling if the product or package is not the same time, however, the facilities must be available to a recyclable to a substantial majority revised Guides do not require substantial majority of consumers (60%) of consumers. A number advertisers to specify whether or communities where the item of commenters to the proposed the recycled content is pre- is sold. The proposed Guides Guides urged FTC to reconsider or post-consumer content. reference FTC’s informal position the use of positive disclosures, To the extent a pre-consumer that a “substantial majority” noting that with the increased use content claim is made, the means 60%. Advertising for of the internet and mobile devices, Guides continue to remind products that do not meet the it is likely consumers would advertisers that they must be “substantial majority” threshold, interpret positive disclosures able to substantiate that the but are recyclable to a “significant differently today. pre-consumer material would percentage” of consumers must otherwise have entered the be qualified; products or packages Recycled Content solid waste stream, the recycled with limited recyclability require Claims material was required to undergo added qualifiers to assure that significant modifications, and consumers are aware of the Guidance on recycled content the recycled material will limited recyclability. FTC also claims also remains relatively not be reused in the original requested comments on whether unchanged. These claims continue manufacturing process. So long it should quantify a “significant to remain subject to a critical as marketers can substantiate percentage.” prerequisite – the material claimed (continued on next page)
Thermoforming QUARTERLY 31
1TFQ 2ND Qtr 11 ins.indd 31 9/12/11 11:33:44 AM these claims on a reasonable programs and/or the percentage basis, the FTC continues to of recycled content used to allow pre-consumer recycled make the product or package, if content claims to be made. less than 100%. With regard to implied claims suggesting both In its proposed Guides, recyclability and recycled content, the Commission requested the proposed Guides declined comments on what changes, if to advise marketers making an any, it should make to existing unqualified recycled content guidance on pre-consumer claims to affirmatively disclose if Our mission is recycled content claims, and their product is not recyclable. requested relevant consumer to facilitate the perception evidence. In RIC advancement of reviewing the public comments The FTC also did not change submitted in response, only its position on the Resin thermoforming 10 out of 340 comments dealt Identification Code (RIC), now directly with the definition of an ASTM International standard. technologies pre-consumer recycled content. Inconspicuous use of the RIC is Critically, the sole commenter not deemed to be a recyclable through opposing the use of pre- claim. Makers of plastic education, consumer recycled content did packaging, however, should be not provide consumer perception careful to use the appropriate application, evidence. Based on FTC’s past code in reference to the material response to comments that failed used. [Ed. emphasis] promotion and to include consumer perception evidence, it is not expected that research. the Commission will change Conclusion its position regarding recycled The FTC’s views on how to assure content claims for products that recyclable and recycled SPE National manufactured with pre-consumer content claims are truthful and not Executive Director recycled materials. misleading in essence has changed Susan Oderwald little from the current Guides. Direct Line: 203/740-5471 Combined One reason is that the FTC’s views Fax: 203/775-8490 Recyclable and on false and deceptive advertising email: [email protected] Recycled Content are driven by consumer perception. The FTC is still in the Claims process of reviewing comments Conference Coordinator Marketers must remain mindful submitted to the proposed Guides, Gwen Mathis that, by itself, the use of the including input on how to quantify 6 S. Second Street, SE Möbius loop likely conveys that the substantial majority threshold. Lindale, Georgia 30147 the product or packaging is both It will likely issue final guidance 706/235-9298 recyclable and made entirely later in the year. Fax: 706/295-4276 from recycled material. Unless email: [email protected] a marketer has substantiation For more information on the for both messages, FTC requires revised Guides, or how your this distinction to be conveyed. company can comply, please Visit Our Such a claim may require contact Sheila A. Millar at (202) Website at: further qualification, to the 434-4143, or [email protected], extent necessary, to disclose the or J.C. Walker at (202) 434-4181, www.thermoformingdivision.com limited availability of recycling or [email protected]. x 32 Thermoforming quarterly
1TFQ 2ND Qtr 11 ins.indd 32 9/12/11 11:33:46 AM COUNCIL SUMMARY
up 33% and ANTEC income tracked result of the leadership of Ken Griep Roger Kipp ahead of budget with expenses at (Division Chair) and Clarissa Schroeder budget. A great start! (Communications Committee Chair) as Councilor Membership has grown above well as the continuing support of our 15,000 with 822 new members and members. membership retention rate of 77%. On Monday May 2nd, I served as PE Council continues to provide The source of new members includes moderator for the Thermoforming Sstable direction for the society. Our conference registrations, Wiley Division’s technical session. The five outgoing President Ken Braney brought Authors, website, and Section and papers presented were excellent and further global recognition to SPE with Division growth. However, the primary featured outstanding attendance. The significant membership stimulation, recruitment tool has been New Member topics included: global corporate outreach, and a Campaigns where over 35% of new • Thermoformability of Radiation broader depth of technology growth. members were signed up. Members Cross Linked Polyamide 12 Ken is a “globalist thinker” with need to reach out to colleagues and • Syntactic Foams For Use As plans in place for worldwide technical promote membership in the society that Plug Assists in Heavy Gage conferences including EUROTEC 2011 is the “trusted technology information Thermoforming (14-15 November in Barcelona, Spain) source” for the plastics industry. If you • Multi-Layer Films for and two exciting new conferences are interested in obtaining a discount in Thermoformed Food Container in India and Japan (ANTEC ASIA). your membership you can do just that Applications Incoming President Russell Broome by bringing in new members. • Influence of Processing will build on the solid foundation put Member value is paramount. Conditions on the in place by Ken. The two leaders are The SPE Foundation is an excellent Thermoformability of PP Sheet working to ensure continuity during the opportunity to find member value. Material transition phase. Russell’s vision is to Since 1997 the Foundation has awarded • Optimization of Molding maintain the global / corporate growth $1.6 million dollars in grants to Conditions of Plug Assisted while focusing on the three key areas educational and continuing education Thermoformed Thin Containers Ken outlined a year ago: Membership, programs for plastics research and Each of these papers will be Revenue, Member Value. education. Scholarships totaling presented as technical articles in While Ken focused on global and $107,000.00 were awarded in 2010 future Thermoforming Quarterly corporate growth, Russell will put to 31 students. The new Association publications. emphasis on expansion of the student, Management System software As in the past, our Division was early career, and Generation Y groups. AVECTRA and accounting system, pleased to be a sponsor for the Student He has added an ad hoc student INTACCT, went live at the end of the Luncheon. The financial support was member to the Executive Committee, first quarter and will begin to provide amazing this year with Divisions and created the Next Generation Advisory member value through service and Sections providing over $30,000 to Board and the Academic Outreach billing options. cover the cost of student attendance Committee that I am proud to chair. and awards. One notable award for our I noted in the last Quarterly the ANTEC 2011 Division was the Outstanding Student importance of SPE regaining and Chapter Award that went to the chapter ANTEC ran from May 1st-5th at the retaining financial stability if we are at Penn College, the home of the Hynes Convention Center in Boston, to continue our mission. I am pleased Thermoforming Center of Excellence. MA. This ANTEC was a huge success to report that with the hard work and With a standing room crowd of over with attendance up by 31% from commitment from staff and Council the 200, the students and guests were 2010. Exhibitors, sponsorship, and recent trend toward financial stability enlightened by a panel of entrepreneurs registration revenues are all above has continued. The 2010 fiscal year sharing advice on the challenges and forecasts. Even more exciting is that ended with revenues up and SPE in the rewards for start-up ventures. there was a flurry of activity relating to black with a $134,000.00 net positive There is still time to present technical our Division. balance. These increased revenues are papers for consideration at EUROTEC The Thermoforming Division was the result of increased membership, 2011. Please contact me for complete awarded the Gold Pinnacle Award for continued global expansion, further details. x corporate sponsorship and increased Outstanding Division performance as well as the Communications Excellence technical product sales. The first Best regards, Award for providing unique and quarter of 2011 is the best first quarter Roger varied communications to members since 1999 with income up 28% and [email protected] expenses down 2%. Webinar sales are and the industry. These awards are the
Thermoforming QUARTERLY 33
1TFQ 2ND Qtr 11 ins.indd 33 9/12/11 11:33:49 AM Executive 2010 - 2012 THERMOFORMING DIVISION ORGANIZATIONAL CHART Chair Committee Ken Griep
Chair Elect Secretary Treasurer Councilor Prior Chair 2010 - 2012 Phil Barhouse Mike Sirotnak James Alongi Roger Kipp Brian Ray CHAIR
2011 Conference Ken Griep Finance Nominating AARC Schaumburg, IL Membership Bob Porsche Portage Casting & Mold Clarissa Schroeder Rich Freeman James Alongi Haydn Forward 2901 Portage Road 2012 Conference Portage, WI 53901 Publications / Antec Grand Rapids, MI Communications Technical Committees Advertising (608) 742-7137 Brian Winton Haydn Forward & Clarissa Schroeder Laura Pichon Fax (608) 742-2199 Lola Carere [email protected] Newsletter / Technical Conference Processing Student Programs Recognition Editor Coordinator Haydn Forward Brian Winton Juliet Goff CHAIR ELECT Conor Carlin Consultant Gwen Mathis Phil Barhouse Spartech Packaging Technologies Materials OPCOM Green Committee 100 Creative Way, PO Box 128 Roger Jean Phil Barhouse Steve Hasselbach Ripon, WI 54971 (920) 748-1119 Machinery Fax (920) 748-9466 Don Kruschke [email protected]
TREASURER James Alongi MAAC Machinery 590 Tower Blvd. Carol Stream, IL 60188 (630) 665-1700 Fax (630) 665-7799 [email protected] SECRETARY Mike Sirotnak Solar Products 228 Wanaque Avenue Pompton Lakes, NJ 07442 (973) 248-9370 Fax (973) 835-7856 [email protected] COUNCILOR WITH TERM ENDING ANTEC 2010 Roger Kipp McClarin Plastics P. O. Box 486, 15 Industrial Drive Hanover, PA 17331 (717) 637-2241 x4003 Fax (717) 637-4811 [email protected] PRIOR CHAIR Brian Ray Ray Products 1700 Chablis Avenue Ontario, CA 91761 (909) 390-9906, Ext. 216 Fax (909) 390-9984 [email protected]
34 Thermoforming quarterly
1TFQ 2ND Qtr 11 ins.indd 34 9/12/11 11:33:54 AM Board of Directors
MACHINERY COMMITTEE MATERIALS COMMITTEE Clarissa Schroeder Stephen Murrill Auriga Polymers, Inc. Profile Plastics James Alongi Jim Armor Film & Sheet Division 65 S. Waukegan MAAC Machinery Armor & Associates 1551 Sha Lane Lake Bluff, IL 60044 590 Tower Blvd. 16181 Santa Barbara Lane Spartanburg, SC 29307 T: 847.604.5100 x29 Carol Stream, IL 60188 Huntington Beach, CA 92649 T: 864.579.5047 F: 847.604.8030 T: 630.665.1700 T: 714.846.7000 F: 864.579.5288 [email protected] F: 630.665.7799 F: 714.846.7001 [email protected] [email protected] [email protected] Dennis Northrop Eric Short Soliant LLC Roger Fox Phil Barhouse Mytex Polymers 1872 Highway 9 Bypass The Foxmor Group Spartech Packaging 1403 Port Road Lancaster, NC 29720 373 S. Country Farm Road Technologies Jeffersonville, IN 47130-8411 T: 803.287.5535 Suite 202 100 Creative Way T: 248.705.2830 [email protected] Wheaton, IL 60187 PO Box 128 F: 248.328.8073 T: 630.653.2200 Ripon, WI 54971 [email protected] Mark Strachan F: 630.653.1474 T: 920.748.1119 Global Thermoforming [email protected] F: 920.748.9466 Technologies [email protected] PROCESSING COMMITTEE 1550 SW 24th Avenue Hal Gilham Ft. Lauderdale, FL 33312 Productive Plastics, Inc. Lola Carere Haydn Forward (Chair) T: 754.224.7513 103 West Park Drive Premier Material Concepts Specialty Manufacturing Co. [email protected] Mt. Laurel, NJ 08045 2715 Maple Park Drive 6790 Nancy Ridge Road T: 856.778.4300 Cumming, GA 30041 San Diego, CA 92121 Jay Waddell F: 856.234.3310 T: 567.245.5253 T: 858.450.1591 Plastics Concepts & Innovations [email protected] F: 770.406.8217 F: 858.450.0400 1127 Queensborough Road [email protected] [email protected] Suite 102 Don Kruschke (Chair) Mt. Pleasant, SC 29464 Thermoforming Machinery & Juliet Goff Richard Freeman T: 843.971.7833 Equipment Kal Plastics, Inc. Freetech Plastics F: 843.216.6151 31875 Solon Road 2050 East 48th Street 2211 Warm Springs Court [email protected] Solon, OH 44139 Vernon, CA 90058-2022 Fremont, CA 94539 T: 440.498.4000 T: 323.581.6194 T: 510.651.9996 Director Emeritus F: 440.498.4001 [email protected] F: 510.651.9917 Art Buckel [email protected] [email protected] McConnell Company Donald Hylton 3452 Bayonne Drive Mike Sirotnak McConnell Company Ken Griep San Diego, CA 92109 Solar Products 646 Holyfield Highway Portage Casting & Mold T: 858.273.9620 228 Wanaque Avenue Fairburn, GA 30213 2901 Portage Road [email protected] Pompton Lakes, NJ 07442 T: 678.772.5008 Portage, WI 53901 T: 973.248.9370 [email protected] T: 608.742.7137 F: 973.835.7856 F: 608.742.2199 [email protected] Roger P. Jean (Chair) [email protected] Rowmark/PMC Brian Ray PO Box 1605 Steve Hasselbach Ray Products 2040 Industrial Drive CMI Plastics 1700 Chablis Drive Findlay, OH 45840 222 Pepsi Way Ontario, CA 91761 T: 567.208.9758 Ayden, NC 28416 T: 909.390.9906 [email protected] T: 252.746.2171 F: 909.390.9984 F: 252.746.2172 [email protected] Laura Pichon [email protected] Ex-Tech Plastics Brian Winton PO Box 576 Roger Kipp Lyle Industries, Inc. 11413 Burlington Road McClarin Plastics 4144 W. Lyle Road Richmond, IL 60071 15 Industrial Drive Beaverton, MI 48612 T: 847.829.8124 PO Box 486 T: 989-435-7714 x 32 F: 815.678.4248 Hanover, PA 17331 F: 989-435-7250 [email protected] T: 717.637.2241 [email protected] F: 717.637.2091 Robert G. Porsche [email protected] General Plastics 2609 West Mill Road Bret Joslyn Milwaukee, WI 53209 Joslyn Manufacturing T: 414-351-1000 9400 Valley View Road F: 414-351-1284 Macedonia, OH 44056 [email protected] T: 330.467.8111 F: 330.467.6574 [email protected]
Thermoforming QUARTERLY 35
1TFQ 2ND Qtr 11 ins.indd 35 9/12/11 11:33:57 AM Thermoforming SECOND QUARTER 2011 Quarterly® VOLUME 30 n NUMBER 2
Sponsor Index These sponsors enable us to publish Thermoforming Quarterly
n Allen...... 13 n Brown Machine...... 29 n CMT Materials...... 10 n CMG...... 13 n GN Plastics...... 6 n GPEC 2011...... 20 n Kiefel...... 13 n KMT...... 20 n Kydex...... Inside Back Cover n MAAC Machinery...... 20 n McClarin Plastics...... 6 n Nova Chemicals...... 11 n PCI...... 34 n PMC...... Back Cover n Portage Casting & Mold...... 6 n Primex Plastics...... 10 n Productive Plastics...... 13 n Profile Plastics Corp...... 13 n PTi...... Inside Front Cover n Ray Products...... 13 n Solar Products...... 6 n Tempco...... 36 n Thermoforming Machinery & Equipment Inc...... 34 n Thermwood...... 7 n TPS...... 7 n TSL...... 18 n Zed Industries...... 13 Thermoforming Division Membership Benefits n Access to industry knowledge from one central location: www.thermoformingdivision.com. n Subscription to Thermoforming Quarterly, voted “Publication of the Year” by SPE National. n Exposure to new ideas and trends from across the globe n New and innovative part design at the Parts Competition. n Open dialogue with the entire industry at the annual conference. n Discounts, discounts, discounts on books, seminars and conferences. n For managers: workshops and presentations tailored specifically to the needs of your operators. n For operators: workshops and presentations that will send you home with new tools to improve your performance, make your job easier and help the company’s bottom line. Join D25 today!
36 Thermoforming quarterly
1TFQ 2ND Qtr 11 ins.indd 36 9/12/11 11:34:03 AM 1TFQ 2ND Qtr 11 Cvr.indd 2 9/12/11 10:51:48 AM 1TFQ 2ND Qtr 11 Cvr.indd 3 9/12/11 10:51:55 AM 1TFQ 2ND Qtr 11 Cvr.indd 4 9/12/11 10:52:02 AM