Hobbies And Interests
Prototype Thermoforming
When prototyping or doing small runs, vacuum thermoforming may be used. With vacuum thermoforming, there is only one mold. It may be the inside of the form or the outside of the form. Vacuum is the force used to seal the composite panel tight to the form.
Heat
Whether it's high-production die-forming or custom vacuum molding, once the mold is ready, the composite panel is heated. The heat will bring the panel to a consistency of thick taffy. It will have to maintain its structure but be easily pliable. Using the right heat for the right type and thickness of composite panel is critical. Too hot, and the material can burn and otherwise deform. Not enough, and the material will not take details of the form.
Vacuum Forming
With vacuum forming, once the form is in place and the panel is heated, vacuum pressure is applied. Vacuum is often applied by creating small holes in the form, then laying the hot composite over the form, within an enclosure. The vacuum pressure sucks the heated, malleable composite to the form. It may be left with partial vacuum momentarily for the composite to cool slightly and set. Once fully cooled, excess material is trimmed.
Die Forming
High production composite thermoforming uses die presses, in the same way the auto industry stamps out car fenders. One form is made for one side and its inverse form is made for the other. Rather than vacuum pressure, mechanical pressure is used to created the form. The heated panel is pressed between the inverse forms while hot. Production thermo molds often trim the excess automatically as part of the forming process.