TECHNICAL BULLETIN 137

Thermoforming
Introduction Surface temperatures should not exceed 380 °F (194 °C).
It is common practice, especially in high production opera-
Several types of acrylic sheets are produced at Aristech tions, to allow surface temperatures to exceed 380 °F (194
Surfaces in Florence, Kentucky. The three most com- °C). Higher temperatures can be tolerated up to 30 sec-
mon thermoformable sheets are GPA (General Purpose onds depending on sheet thickness in most cases. But
Acrylic), Acrysteel I-GP (Impact Resistant Acrylic), and I-300 due to blistering potential, it is not recommended to exceed
(Crosslinked Acrylic). All three products have very good 380 °F (194 °C).
thermoformability, which is one of many important and
useful properties offered by Aristech Surfaces . With Figure 2 outlines the heating cycles when using electric
many products available, there is an Aristech Surfaces
Acrylic Sheet to satisfy most needs and application require- infra-red radiant heaters on one or two sides. Again,
ments. heating times can vary depending on the type of heating
equipment used, percentage times, distance between
GPA is ideally suited for all types of outdoor signs, skylights, sheet and heaters, and heat loss factors.
and general fabrication. This weather-resistant acrylic is
solvent cementable and is inventoried in many colors,
thicknesses and sizes.

lGP Impact Resistant Acrylic offers the same high perfor-

mance qualities as GPA plus additional impact resistance
to reduce breakage in handling, manufacture, and trans-
portation.

I-300 is a partially cross-linked Aristech Surfaces Acrylic

Sheet with unparalleled performance for the more de-
manding thermoforming application requiring stain and
chemical resistance. This product is most commonly used
in the plumbingware and spa markets.

Good formability is one of the most important and useful 0.100 0.200 0.300 0.400
properties of Aristech Surfaces Acrylic Sheet. When Thickness - Inches
Aristech Surfaces sheet has been properly heated, it FIGURE 1. - Forced Air Circulating Oven at 350 °F (177 °C)
feels like a sheet of soft rubber. In this state the material can
be formed to almost any desired shape. On cooling, the
acrylic becomes rigid and retains the shape to which it has
been formed. Forming thermoplastic sheet is probably the
simplest type of plastic fabrication. The cost of molds and
equipment is relatively low. Both two and three dimen-
sional forming of Aristech Surfaces Acrylic Sheet can be
accomplished by a number of different methods. The
selection will depend on the shape, thickness, tolerance
and optical quality required for the formed part as well as
the equipment available and number of parts to be made.

It is imperative that all of the above Aristech Surfaces

Acrylic products be heated properly for thermoforming. Too
low forming temperatures on these products will leave
stresses in the formed part that could possibly be relieved
by solvents in reinforcing resin, paint and decorating ma-
terials causing cracks or crazing. Too high forming tem-
peratures can cause sheet blistering.

Thermoforming Temperatures and Cycles

The following curves (Figures 1 & 2) were derived from

tests performed at Aristech. Due to the large variety of
.050 .100 .150 .200 .250
heating equipment available, heating times may vary. The
following heating cycles should be used as a starting point Thickness - Inches
only in obtaining optimum forming temperature times and
FIGURE 2. - Electric Infra-red Radiant Heating
cycles. The temperature and cycle times depend upon the
thickness of acrylic sheet as well as the type of heating and
forming equipment used.

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Several other methods can be used to determine if a sheet More uniform heat distribution can sometimes be accom-
has been sufficiently heated. The most common is the plished by mounting a fine wire-mesh screen between
ripple method by which the operator shakes the heated the sheet and the heat source. A device to control the
sheet with a non-combustible object (See note). When energy input, such as a variable transformer, or percent-
the sheet ripples uniformly across the surface, it is ready age timers should always be used to control sheet tem-
for forming. Another commonly used technique is the “sag peratures. Top infra-red heaters should be approximately
method”. By trial and error the amount of sag in a hot 12" (30 cm) from the sheet. Bottom heaters can be 18 to
sheet can be correlated with the optimum time to be 20" (45 to 50 cm) away.
thermoformed. The best procedure for determining when
the sheet is ready for forming is to accurately control the
temperature by the use of heat sensors and/or tempera-
ture indicating stickers and crayons. The actual cycle, tem-
perature settings and techniques most suitable for a par-
ticular forming job are best determined on one’s own
equipment.

Note:
Care must be taken to make sure the operator does not
endanger him/herself due to exposure to electricity, hot
oven components, or hot sheet.

Heating Equipment

1. Forced Air Circulating Ovens

Forced air circulating ovens generally provide uniform
heating at a constant temperature with the least danger of
overheating the acrylic sheet. Electric fans should be used
to circulate the hot air across the sheeting at velocities of
approximately 150 ft./minute (46 m/minute). Suitable
baffles should be used to distribute the heat evenly
throughout the oven. Heating may be done with gas or 3. Strip Heating
electricity. Gas ovens require heat exchangers to prevent Strip heating is sometimes used for specialized forming
the accumulation of soot from the flue gas. Electric ovens jobs. For example, a strip heater can be used to make
can be heated with a series of 1000-watt 3strip heating3 simple bends in Aristech Surfaces Acrylic Sheet. Strip
elements. An oven with a capacity of 360 ft (10 m ), for heaters can be purchased from plastics suppliers or can
example, will require approximately 25,000 watts of input. be constructed from “Nichrome” heating elements en-
About one-half of this input is required to overcome heat- cased in ceramic or “Pyrex” tubing. To prevent distortion or
ing losses through the insulation, leaks and door usage. damage to the sheet surface, the Aristech Surfaces
An oven insulation at least two inches thick is suggested. Acrylic Sheet should be kept at least 1/2" (13 mm) away
Oven doors should be narrow to minimize heat loss, but from the hot tube. See Figure 4 for typical strip heater
at least one door should be large enough to permit re- arrangement.
heating of formed parts which may require reforming. The
oven should have automatic controls so that any desired
temperature in the range of 250 to 450 °F (121 to 232 °C)
can be closely maintained. In addition, temperature
recording devices are desirable, but not essential. Uni-
form heating is best provided when the sheet is hung
vertically. This can be accomplished by hanging the sheets
of acrylic on overhead racks designed to roll along a mono-
rail mounted in the oven roof or in a portable unit. Precau-
tions should be taken so that the sheet cannot fold or
come in contact with another. A series of spring clips or a
spring channel can be used for securely grasping the
sheet along its entire length.
2. Infra-Red Heating
Infra-red radiation can heat Aristech Acrylic Sheet three to
ten times faster than forced-air heating. This type of heat-
ing is often used with automatic forming machines where
a minimum cycle time is important. Temperature control,
however, is much more critical and uniform heating is
more difficult to obtain by this method. Acrylic plastic ab-
sorbs most of the infra-red energy on the exposed sur-
face, which can rapidly attain temperatures of over 360 °F
(182 °C). The center of the sheet is heated by a slower
conduction of heat from the hot surface. This usually
causes temperature gradients across the thickness. The
gradient is more severe with infra-red heating from one
side only. (See Figure 3). Infra-red radiant heat is usually
supplied by reflector backed tubular metal elements, re-
sistance wire coils or a bank of infra-red lamps.

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Three-Dimensional Forming

Techniques for three-dimensional forming of plastic gen-

erally require vacuum, air pressure, mechanical assists
or combinations of all three to manipulate the heated sheet
into the desired shape. The basic forming techniques used
for Aristech Surfaces Acrylic Sheet are illustrated in the
following drawings and described below.

1. Vacuum Forming

A. Heated sheet in clamp frame.

B. Mold is mechanically positioned to heated sheet, forming
a seal. Vacuum is then applied to form part.

2. Drape/Vacuum Forming

A. Heated sheet in clamp frame.

B. The mold is forced into the sheet to a depth that forms a
seal around the periphery. Vacuum is then applied to
form the part.

3. Vacuum/Snap-Back Forming

A. Heated sheet in clamp frame.

B. Position vacuum chamber to heated sheet to form seal.
Apply vacuum to form bubble to predetermined height.
C. Insert mold into heated/prestretched sheet to form seal.
Air control relieves vacuum in preform vacuum chamber.
Apply vacuum to mold to form part.

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A. Heated sheet in clamping frame.
B. Position pressure chamber into heated sheet to form seal.
Apply pressure to prestretched sheet to controlled height.
C. Insert mold into prestretched bubble at a controlled rate.
Insert to depth required to form a seal.

A. Heated sheet in clamping frame.

B. Position mold into heated sheet to form seal. Insert heated
plug at controlled rate to the depth required for preforming.
C. Apply vacuum to form part.

A. Heated sheet in clamping frame.

B. Position mold into heated sheet to form pressure seal. Apply
pressure to prestretch sheet to controlled height.
C. Insert heated plug into bubble at a controlled rate to the depth
required for preforming.
D. Apply vacuum to form part.

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MOLDS

WOOD—Wooden molds are easily fabricated, inexpensive can be used br medium production runs and have good
and can be altered readily. Wood molds are ideal for short durability provided they are properly fabricated.
production runs where mold markoff is not important and
for prototyping. ALUMINUM—Aluminum molds are used in high pro-
duction operations. Aluminum moIds will last indefinitely
EPOXY—Epoxy molds yield the least amount of mold with little maintenance required.
markoff of any of the mold materials used. Epoxy molds

Thermoforming Troubleshooting Guide

Problem Probable Cause Corrective Action

Blistering. Sheet too hot. Reduce time heaters or reduce voltage.

Move heater farther away. use screening if
localized.

Poor definition of detail. Sheet too cold. Increase heat input to sheet.
Incomplete forming.
Low vacuum. Check for leaks in vacuum system. Increase
number and/or size of vacuum holes. Add
vacuum capacity.
Sheet too thick. Use thinner caliper sheet.
Low air pressure. Increase volume and/or pressure.

Excessive thinning at bottom of Poor technique. Change forming cycle to include billowing or
draw or corners. plug assist. Use screening to control
temperature profile.
Sheet too thin. Use thicker sheet.
Drawdown too fast. Decrease rate of drawdown.

Extreme wall thickness Uneven sheet heating. Check temperature profile.

variations. Mold too cold. Change heaters to provide higher uniform
mold surface temperature. Check cooling
system for scale or plugs.
Sheet slipping. Adjust clamping frame to provide uniform
pressures.
Stray air currents. Provide protection to eliminate drafts.

Excessive sag. Sheet too hot. Reduce time or temperature.

Pits or pimples. Vacuum holes too large. Use smaller holes.

Vacuum rate too high. Decrease vacuum rate or level.

Dirt on mold or sheet. Clean mold and/or sheet.

Part sticking to mold. Rough mold surface. Polish mold.

Undercuts too deep. Reduce undercuts. Change to split mold.
Not enough draft. Increase draft of mold.

Mark-off. Dirt on sheet. Clean sheet.

Dirt on mold. Clean mold.
Dirt in atmosphere. Clean vacuum forming area. Isolate area if
necessary and supply filtered air.
Sheet too hot. Reduce heat and heat more slowly.

Distortion in finished part. Part removed too hot. Increase cooling time before removing part.
Check cooling system.
Uneven heating. Check temperature profile.
Correct mold design — stiffen to eliminate.

Tearing of part on forming. Mold design. Increase radius of corner.

Sheet too cold. Increase heating time or temperature.

Bridging. Mold design. Add take-up blocks to pull out wrinkles.

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 For cautions and other information relating to handling of an
exposure to this product, please see the applicable material
safety data sheet published by Aristech Surfaces.

These instructions are based upon experience with Aristech Surfaces products only. Experience with products of other
manufacturers is specifically disclaimed. For most uses, check for local code approval and test for application suitability.
These procedures, techniques and suggested materials should only be used by personnel who are properly trained in
the safe handling of the chemicals and the equipment with which they are working. Avoid aromatic solvents, clean with
mild soap and water, avoid abrasives. These suggestions are based on information believed to be reliable, however,
Aristech Surfaces makes no warranty, guarantee, or representation and assumes no obligations or liability as to the
absolute correctness or sufficiency of any of the foregoing, or that additional or other measures may not be required under
particular conditions or circumstances.

7350 Empire Drive • Florence, KY 41042

(859) 283-1501 • Toll Free 800-354-9858
www.aristechacrylics.com May 2014
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