Vacuum forming. Equipment for vacuum forming of plastics and films

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1. Vacuum forming of plastics
2. Vacuum film forming
3. Vacuum molds
4. Vacuum forming method
5. Plastic Vacuum Forming Machine

Vacuum forming is a technology for forming products using hot vacuum. This type of production is carried out using plastic materials that, under the influence of a hot vacuum or low pressure, are able to change their shape. This method of manufacturing products is in most cases used in the serial production of large-sized plastic products, but it is possible to use it in individual production of plastic molds.

Vacuum forming option

The principle of vacuum forming is to place sheet plastic under or above the workpiece, and by heating under vacuum, the plastic repeats the shape of the required workpiece exactly down to the millimeter. All types of blanks are referred to as a matrix, which is the basis for any shape of the future product.

The main benefits of using the vacuum forming method:

• It is possible to use plastic, the thickness of which, depending on the characteristics of the desired product, ranges from 0.04 to 7 mm, and as for the final dimensions of the product, they can reach 5 m in diameter;
• The finished product can be separated from the matrix manually;
• Low billet price;
• Relatively low price for installing a vacuum forming system.

To form the finished product, a fairly wide range of materials is used: plastic, transparent or colored acrylic, polystyrene, PVC, polycarbonate, and so on. A negative factor in the manufacture of such products is that it is impossible to create a workpiece, one of the angles of which will be less than 90 degrees.

Vacuum forming of plastics

Today, plastic molds can fully replace similar products that previously led in industrial production. This type of molding is used for mass production and for individual copies of products. Thanks to modern vacuum forming units, product designs can have very creative shapes that satisfy a huge range of production areas. The following materials belong to the category of plastic:

1. Plexiglas. This material is polymethyl methacrylate plastic or acrylic, and in its standard form it is completely transparent, but if necessary, its color can be changed by adding dyes of any shade. Before using this type of material, it must be thoroughly dried, as it is prone to intense absorption of moisture from the environment. Among the disadvantages of using this raw material, it can be noted that in the process of forming the necessary product, a large amount of electricity is consumed, but this is more than compensated by the durability of the finished product, which is used in advertising stands, in the production of volumetric numbers and letters, and other product details for advertising campaigns .
2. ABS plastic. This material can be easily vacuum formed and has amazing shock-absorbing qualities. Due to this, the main purpose of using this material is the manufacture of sports equipment. In addition, it can be emphasized that ABS plastic can withstand heating up to 90 degrees during the molding process.

Vacuum forming of plastics

Vacuum forming methods

Depending on how the molded material contacts the mold, there are:

• Free forming. With this method, the processed material does not come into contact with the metal parts of the mold. This method has limitations; transparent acrylate plastics are processed using this method. Heating should be very uniform. to avoid variations in thickness and differences in the optical characteristics of the product. This is how, for example, car headlights are produced;
• Negative molding. Products with this method have an outer surface identical to the surface of the inner part of the matrix. This method has a serious drawback - when a heated sheet blank comes into contact with a cold mold, the material cools sharply. Further molding processes on the bottom and walls proceed unevenly, so the product has different thicknesses
• Positive molding. The essence of the technique is similar to the previous one, only the molding takes place on the punch. The disadvantages of this method are similar; it is impossible to mold a product with sharp corners or great depth.

Vacuum film forming

One of the varieties of molding material is PET film, which is very simple and technologically convenient in the process of vacuum molding. This material does not require advance drying, has low internal stress, and has a reduced heat capacity, which greatly saves the cost of using electricity in the process of molding parts from vacuum film. Thus, the characteristics of the manufactured elements contribute to wide application in the advertising and lighting fields.

Vacuum film forming

Production stages

The first stage in the production process is the production of a sheet or film blank of a polymer material. For this you need an extruder. Some enterprises manage to work without the sheet extrusion molding process; it is enough to simply purchase ready-made materials.

At the second stage, the workpiece is fed to the heating table. or it is pre-fixed in the frame and the heater is lowered from above. The key feature of this stage is uniform heating of all parts of the sheet. Otherwise, there is a high risk of getting a product of different thicknesses.

Next, the sheet enters a sealed chamber in which increased pressure is created. The sheet is molded into the so-called “DOME”. In this way, the sheet is prepared for further processing.

The mold is placed into a sealed chamber. Place it directly under the formed dome. Next, a reduced pressure is created in the forming chamber, which allows the sheet to tightly fit all shaped parts of the mold.

The finished processed product is sent for cooling. The final stage of production is product quality control. It allows you to identify and reject illiquid products.

Vacuum molds

There are two types of mold material used in the vacuum forming process:

1. MDF forms

The simplest, most inexpensive and fastest option for making molds is CNC milling of MDF boards. The required thickness is collected from such plates and, in accordance with the 3D model, which is programmed in the CNC, the required shape is milled. After final milling of the part, it is dried and treated with a special solution, and finally the surface is treated with grinding material, after which it can already be used for vacuum forming. Depending on the complexity of the matrix shape or, in other words, the blank, the difference in the number of cycles differs when used. Thus, if the shape has rounded edges and low protrusions, then the amount of use can reach up to 500 times. But if the structure consists of sharp corners and high protrusions, then its durability is significantly reduced, and there will be a need to restore the blank. But restoration in most cases is a fairly cheap process, due to the low price of materials for re-production.

1. Fiberglass molds

This material can be used more times than MDF. The technology for producing such a matrix is ​​that it is first necessary to have a hollow blank into which a polymer resin reinforced with fiberglass is poured. This procedure takes a significant amount of time, but it more than pays off due to repeated use of the form in the future. In addition, if it is necessary to produce, for example, 10 identical products in one cycle using vacuum forming, then the use of fiberglass makes the reproduction of blanks much cheaper, in contrast to MDF forms.

Materials and scope of products

Thermovacuum molding is the process of producing three-dimensional products from thermoplastic polymer materials under the influence of temperature and vacuum. Almost all sheet thermoplastics are used as raw materials, among which the following are most often used in mass production:

• polyethylene (including foamed);
• PVC;
• polypropylene;
• polymethyl methacrylate (PET);
• ABS plastic (acrylonitrile butadiene styrene);
• polystyrene;
• polycarbonate;
• plexiglass.

Vacuum forming of sheet plastic allows us to produce products that are in demand in:

1. automotive, aviation industry;
2. shipbuilding and medicine;
3. instrument making and energy;
4. food production;
5. fields of construction and design.

The use of a particular material depends on the features and technical characteristics of the equipment, the ability to create pressure and the heating temperature.

In everyday life, each of us regularly encounters products made by vacuum thermoforming. An example of this could be:

• wash tubs, sinks and shower trays;
• disposable tableware;
• bumpers and car tuning items;
• signs with three-dimensional letters, advertising, etc.

In the process of individual production of products using this technology, relatively uncomplicated, small-sized and inexpensive vacuum forming machines are used.

As a rule, such devices consist of a housing, a pressure frame, a fan and a heating element, which is played by a heating element. The main part of the machine is a vacuum pump that pumps air out of the chamber with the heated workpiece.

In serial production, high-tech vacuum forming equipment is used, which allows you to create products in a continuous conveyor mode. All models for creating plastic products using vacuum thermoforming can be divided into two categories: automatic and semi-automatic. Firstly, all processes are carried out without human intervention. Secondly, the process of laying, fixing and removing the polymer blank is carried out manually.

Vacuum forming method

To create products using vacuum forming, you first need to purchase an appropriate vacuum forming machine. Regarding the materials that are necessary to create products, their type depends on the field of activity of the enterprise and the further area of ​​application of the finished products. The main requirement for raw materials for production is the same thickness of all sheets for a single series of parts.

The vacuum forming procedure can be divided into 2 stages:

• Making blanks;
• Vacuum formation using a matrix of selected material.

Regarding the manufacture of the matrix, it should be noted that this process takes quite a bit of money, since the main material for the manufacture of blanks is MDF or fiberglass. There are other types of materials, such as duralumin, aluminum, all kinds of resins, and so on, but their use is only advisable in industries where the production of molding products is based on a constant serial cycle.

The molding itself begins with the raw sheet being attached to the matrix frame of the machine, which, by the way, must be thoroughly cleaned of all kinds of dust and contaminants, since otherwise these components will become one with the finished product. In the middle there is a matrix element or a series of blanks, with multiple production in one cycle. For vacuum forming, there is a heated panel above the frame with the material, which must be lowered onto the sheet being formed so that the installed material is heated to the desired temperature and takes the shape of the matrix.

Korst ABS

SPECIAL OFFER for the production of promotional products and plastic products!

Using the equipment produced, it is possible to vacuum form (vacuum forming) various parts: cases, tuning items, forms for various purposes, trays, racks, inserts of packaging elements, etc. having various applications in many industries. Vacuum forming is a technology based on the use of thermoplastic materials (TPM) in a heated (“hot”) form by subjecting them to vacuum or very low pressure. To carry out vacuum forming, it is necessary and sufficient to comply with a number of conditions: - the use of TPM, - the absence of negative angles (less than 90°), - the creation of a vacuum between the material used and the matrix. Vacuum forming has a number of advantages over other methods of producing TPM products.

• Wide range of thicknesses of materials used from 0.05mm to 5mm
• The geometric dimensions of the resulting products are up to several meters
• Relatively low cost of the matrix (possibility of its manufacture from scrap materials (MDF, wood, aluminum, etc.)
• Large range and low cost of consumables
• Possibility of simultaneous formation of parts of various geometric sizes
• Replication of parts (serial production)
• Production that does not require highly qualified personnel, large raw materials and technological costs

Various types of acrylics (milky, transparent, tinted), polystyrene, ABS plastic, PVC, polyethylene, this is not a complete list of materials that can be used for work.

stanki58.ru

Plastic Vacuum Forming Machine

The machine installation proposed for independent production involves a structure with a fixed matrix with an attached modification, to which a frame moves, into which the raw material is pressed for the purpose of molding; in the upper part of the structure there is a heater. The vacuum is formed by a vacuum pump, which creates a vacuum. After heating the plastic, a vacuum is introduced and the manufacturing itself takes place. As soon as the raw material has received the established shape, the vacuum is turned off and it is possible to remove the sheet with the finished shape. It is possible to mold from 1 to several 10 products at a time - it all depends on the scale of the machine’s workbench and the volume of modification. It only remains to add that the average period of the molding cycle takes from 40 to 120 seconds. – everything depends on the thickness of the material and the complexity of the product itself.

Plastic Vacuum Forming Machine

Vacuum forming machines (VFM)

Specifications:

At the request of the customer, the dimensions of the forming table can be changed. VF A550 can be equipped with: a rolling and cutting machine designed for cutting blister packs; a device for welding a blister to cardboard or plastic.

• Ceramic infrared heaters

Specifications:

At the request of the customer, the dimensions of the forming table can be changed. The VF can be equipped with: a rolling and cutting machine designed for cutting blister packs; a device for welding a blister to cardboard or plastic.

• Ceramic infrared heaters

Specifications:

At the request of the customer, the dimensions of the forming table can be changed. The VF can be equipped with: a rolling and cutting machine designed for cutting blister packs; a device for welding a blister to cardboard or plastic.

• Ceramic infrared heaters

Specifications:

At the request of the customer, the dimensions of the forming table can be changed. The VF can be equipped with: a rolling and cutting machine designed for cutting blister packs; a device for welding a blister to cardboard or plastic.

• Ceramic infrared heaters

Specifications:

At the request of the customer, the dimensions of the forming table can be changed. The VF can be equipped with: a rolling and cutting machine designed for cutting blister packs; a device for welding a blister to cardboard or plastic.

• Ceramic infrared heaters

Thermoforming equipment for sheet molding and roll forming. We offer equipment with manual control (the molding cycle is fully controlled by the operator), semi-automatic (the entire molding cycle, except for laying the workpiece and removing the finished product, can be carried out according to a given program without the participation of an operator), and also for large runs we can offer an automatic thermoforming line with productivity from 4 to 10 cycles per minute.

Vacuum Thermoforming Machine: Why should you buy thermoforming equipment from us?

1. Technical and legal support of the transaction.
2. Optimal price-quality ratio.
3. The range of manufactured products ranges from skin packaging to acrylic bathtubs.
4. By purchasing our equipment for vacuum molding of plastic, we will train your employees to work on it.
5. Warranty and post-warranty service.
6. All components are manufactured in Europe at leading factories.
7. We have a wide range of spare parts in our warehouse.
8. Manufacturing of equipment individually according to your specifications.

Equipment Characteristics of Vacuum Forming Machine

• Personal, individual developments that have no analogues.
• Pneumatic system “CAMOZZI” (Italy)
• Ceramic infrared emitters FTF. (Germany)
• SCHMALZ vacuum ejectors. (Germany)
• The thickness of the molding material is film from 0.1 mm, sheet up to 20 mm.
• Cycle time from 30 seconds to 3 minutes. (semi-automatic)
• Ability to adjust the temperature of the heating panel by group and each heater
• Possibility of installing a Siemens, Mitsubishi logic controller.

The most commonly ordered thermoforming machines (by forming table size):

• 300*500 mm
• 600*500 mm
• 1000*600 mm
• 1000*1000 mm
• 1000*1500 mm
• 1000*2000 mm
• 2500*1500 mm
• 2000*3000 mm

Example of a request for a vacuum forming machine (vacuum former)

Vacuum forming machine 5 series

1. It is necessary to thermoform skin packaging made of polystyrene, table size 1500*1000 mm.

2. You need equipment for making core packaging (for cakes, pastries, etc.)

3. It is necessary to mold seedling cassettes from plastic.

Dear Sirs!

Based on your request, we will send you a description of our equipment, which can be ordered this year. We hope that you will like the equipment and that your company will choose our products.

Specifications

Power supply

Equipment

Vacuum

Vacuuming is carried out by a vacuum pump

Vacuum ejector.

or

The pneumatic vacuum system is equipped with equipment from Camozzi (Italy).

IR heating panel

Types of IR heating panels:

Ceramic infrared emitters.

The energy of infrared radiation that hits an object is absorbed by it, transmitted, or reflected from its surface. Most industrially processed materials can be easily heated with infrared rays, because... their greatest absorption capacity is observed at wavelengths between 3 - 10 microns in the infrared region of the spectrum. Because Since heating by infrared radiation is non-contact, energy transfer from the emitter to the object occurs very quickly. Ceramic infrared emitters operate in vacuum and other working environments.

Three heating zones.

Cooling.

2 Axial Fans

Pressure frame.

The clamping frame is made of 10 I-beams and is provided with rulers for dividing the molding field (reducing the molding field).

Lower machine table frame.

The lower frame of the machine table is made of 30x30 timber and is provided with rulers for dividing the molding field (reducing the molding field).

Working chamber.

The working chamber is made hermetically sealed, which allows the material to reach the desired height when heated. It is also provided with an emergency valve (to prevent the table from falling if the vacuum molding chamber is poorly sealed).

The forming table is provided with a 1 inch vacuum opening.

Maximum table power (mold weight) -890 kg. At 10 Atm.

Protection.

Protection is installed to avoid overheating of the rear of the machine. This ensures more uniform heating of the material.

Operating mode

Two operating modes: manual and semi-automatic (sheet insertion and removal are performed manually, the rest of the machine operation is performed automatically).

Availability of a manual operating mode for manual molding and adjustment of the VFM.

Our company can offer you a vacuum forming machine MVF-5 (VFS)

With ceramic infrared emitters - 660,000 rubles.

Additional equipment

Compressor.

Warranty service for a period of: 12 months.

Production time is 30 calendar days.

The machine is designed for sheet size 1000x1500mm.

At the customer's request, we can manufacture a machine for any sheet size.

Prepayment is 70%, the remaining 30% after delivery. (By prior agreement, prepayment can be divided into several stages).

www.promnagrev.ru

Reviews of our plastic products

We made equipment and parts for casting. We were completely satisfied with both the price of the molds and the quality of the casting. We continue cooperation. Mikhail, MirBTH LLC

We started working from scratch. The price of casting is completely satisfactory and the main thing is that you don’t have to constantly take care of the equipment. Andrey, Spetsmontazhprom LLC

We have been cooperating for more than 5 years in casting. The quality of the parts is pleasing and so is the flexibility of the management. We look forward to long-term cooperation. Vasily BytTekhnika LLC

We are making a gear to participate in the tender. Everything was done in a short time. We completed it within 1 month from the moment of ordering - before the product was released