Difference between revisions of "Vacuum Former"

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|Has make=Formech
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|Has model=508DT
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|Has serial number=2728
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  |Has certification=https://georgefox.instructure.com/courses/1305
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|Has make=Formech
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  |Has ace=Needed;Makerhub@georgefox.edu
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|Has model=508DT
 
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  |Has ace=Nathan Bodenman;nbodenman18@georgefox.edu
 
 
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__TOC__
  
 
==Description==
 
==Description==
  
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The Formech 508DT Vacuum Former is a plastic molding machine that utilizes a vacuum to stretch a thin piece of plastic over a mold. The vacuum former is great for thin plastic molds, although there are some limitations on the shape and size.  
+
The Formech 508DT Vacuum Former is a plastic molding machine that utilizes heat and a vacuum to stretch heated plastic over a mold. The vacuum former is great for thin plastic molds, although there are some limitations on the shape and size. The max dimensions for the mold are 17”x19” with a depth of 7.3". The max thickness for the plastic sheet is 0.25"  Molds can be made from many types of materials.  It's fairly common to see molds made from wood.  Molds need to have some draft so they can be removed from the plastic.   
 +
 
  
  
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====Terminology====
 
====Terminology====
  
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* '''The table-''' The bed that the mold rests on.
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* '''Table-''' The bed that the mold rests on.
−
 
+
* '''Clamp Frame-''' The metal bars that captivate the plastic sheet as its heated and stretched over the mold.
 +
* '''Toggle Clamp Screws-'''
 +
*'''Draft Angle-''' The wall angle of a mold. This helps in removing the plastic off the mold. 
 
Knowing what the different buttons in the touchscreen operation mean is important in operating the vacuum former. The three primary ones are heat , vacuum , and release . For a full list, refer to the manual.
 
Knowing what the different buttons in the touchscreen operation mean is important in operating the vacuum former. The three primary ones are heat , vacuum , and release . For a full list, refer to the manual.
  
−
==Training==
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[[Media:Manual-508DT.pdf|Vacuum Former User Manual]]
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====Overview====
 
  
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The disc sander allows you to sand outside corners and flat surfaces using an abrasive disc. The belt can perform inside corner and flat surface sanding. The table angles can be adjusted to change the angle of cuts. The sanding table can be set between 15 and 45 degrees. The belt arm can be adjusted between 0 and 90 degrees with the arm locking handle.  It is important to inspect the sanding disc and belt for wear before use. If you notice any holes or cuts in a belt let the supervisor know before trying to power the machine.  Tears can be caused by leaving material in the same spot too long. Try to keep work moving across the belt/disc to prevent damage. The disc normally won't tear but it will turn dark and have burn marks.
+
[[Media:Vacuum Forming Guide 200715.pdf|Vacuum Forming Guide]]
  
−
====Demonstration====
+
==Training==
 +
====Operation====
  
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You will need to demonstrate the safe setup and use of the belt/disc sander.  You will be sketching an arc onto a piece of scrap material and sanding up to the line using the disc and belt. Make sure to keep the material moving to prevent burning and tearing of the sanding belt/disc.
+
The vacuum former can mold up to a 19"x17" square and to a depth of 7.3".  
  
−
====General Procedure====
+
Molds must slant outwardly slightly to ensure that they can be popped out of the plastic after molding is finished.
  
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1. Obtain a piece of scrap wood. If the work piece is too small it will be difficult to hold onto and create a dangerous situation by placing your fingers too close to the belt/disc.
+
====Demonstration====
  
−
2. Using a pencil or pen sketch a radius or line onto the edge of your material.
+
The demonstration for the vacuum former can use one of the provided demonstration molds or a mold that the trainee brings. The trainee must show that they can set up the vacuum former and mold a part.
  
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3. Make sure the belt and disc are in good shape and secure.
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====Operation====
  
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4. Connect the dust collector hose to the sander.
+
[[File:Formech_Controls.JPG|none|thumb|600x600px]]
  
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5. Power on the dust collector and sander.
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== Operation ==
−
 
+
* Place a mold into the tray and lower it.
−
6. Place the material onto the table and slowly feed your material into the belt/disc using both hands for a rigid grip. Make sure your hands/fingers are clear of any moving parts.  
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* Mold cannot be concave and must slant outwards slightly or it will not be removable from the plastic.
−
 
+
* Place plastic into the clamps ensuring it completely covers the white seals.
−
7. Keep the material moving to prevent too much heat in one spot.
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* Turn on the heaters and set the temperature. The temperature should be 80-120 degrees Celsius.  
−
 
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* The heaters should take about 15 minutes to warm up.
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8. Keep sanding until you cut the material back to your line.
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* After 15 minutes roll the heater over the plastic
−
 
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* Allow the heater to sit over the plastic for 90 seconds if the plastic is 1.8mm thick or 180 seconds if the plastic is 3.3mm thick.
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9. When you are finished sanding power down the dust collector and sander.
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* DO NOT OVERHEAT PLASTIC! this will cause the plastic to develop webbing after the vacuum which will ruin the mold.  
−
 
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* Lift the table.
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10. Make sure all motion has stopped before cleaning the machine.  
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* Turn on the vacuum.
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* Let the plastic cool, then hit the release button.
−
11. Reset the space.
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* Lower the table to remove the plastic.
 +
* Reset the table.
  
 
==Safety==
 
==Safety==
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* Sanding creates heat due to the friction. keep material moving to prevent damage to the sanding belt/disc.  
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* Parts of the machine can reach over 300 degrees C. Don't touch the heater or heat shield surrounding the heater.  
−
* Never put your hand in a position that slipping could cause you to make contact with the belt or disc.  
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* Never put your hand in a position it could be pinched by the molding frame.  
−
* Never reach over the machine while working or turning off the power.  This can be very dangerous as you or your clothing could make contact with the spinning belt or disc.
+
* The formed plastic is very hot and sticky.  It could stick to you and continue to burn if you touch it.  
−
* Use a brush when clearing sawdust from the tables, not your hands.
+
* Some types of plastics could give off toxic fumes when heated. Check the SDS before working with materials you are unfamiliar with.
−
* Use light pressure when removing material.  Never try to force feed the machine.  
 
−
* Avoid kickbacks by sanding on the correct side of the disc. Always sand on the downward side of the disc, which is just left of center on a disc rotating counterclockwise. Sanding on the wrong side is dangerous and can pull material out of your hands.
 
  
 
==Certification==
 
==Certification==
−
[https://foxtale.georgefox.edu/moodle/course/view.php?id=30803 Foxtale Course]
+
Complete <strong>The Vault - {{PAGENAME}} Module</strong> at the link below to gain access to the {{PAGENAME}}. The Maker Hub Canvas course pertains to all facilities and equipment contained in the Maker Hub; simply complete the quizzes for the facilities/equipment you wish to use in the Maker Hub. Please email <span style="color:blue">makerhub@georgefox.edu</span> if you have any questions.
 +
 
 +
[https://georgefox.instructure.com/enroll/GH36RT Maker Hub Canvas Course]
  
 
==Troubleshooting==
 
==Troubleshooting==
−
If belts have hole or tears they need to be replaced.
+
Make sure to put draft on your form to prevent sticking.  
−
Burnt discs need to be replaced.
+
If the plastic is not hot enough it won't pull down over the form.
 +
If the plastic is too hot then it will develop webbing during the vacuum
  
 
==Maintenance==
 
==Maintenance==
 
====General maintenance====
 
====General maintenance====
−
 
−
The following items need to be periodically lubricated:
 
−
* Idler slide (use non hardening grease)
 
−
*Table trunnion (use non hardening grease)
 
  
 
====Specific Maintenance Tasks====
 
====Specific Maintenance Tasks====
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!Done By
 
!Done By
 
|-
 
|-
−
|Replace sanding Belt/Pad
+
|Inspect
 
|As Needed
 
|As Needed
 
|Ace/Tech
 
|Ace/Tech
 
|}
 
|}
−
 
−
== Operation ==
 
−
* Place a mold into the tray and lower it.
 
−
* Mold cannot be concave and must slant outwards slightly or it will not be removable from the plastic.
 
−
* Place plastic into the clamps ensuring it completely covers the white seals.
 
−
* Turn on the heaters. They should take about 15 minutes to warm up.
 
−
* Lift the table.
 
−
* Turn on the vacuum.
 
−
* Let the plastic cool, then hit the release button.
 
−
* Lower the table to remove the plastic.
 
−
* Reset the table.
 
−
 
−
== Specifications for Molds ==
 
−
The vacuum former can mold up to a 19"x17" square and to a depth of 7.3".
 
−
 
−
Molds cannot be concave in any way.
 
−
 
−
Molds must slant outwardly slightly to ensure that they can be popped out of the plastic after molding is finished.
 
−
 
−
== Documentation ==
 
−
* [https://formech.com/wp-content/uploads/Manual-508DTFS_UK_070116_lowres.pdf Formech Vacuum Former Manual]
 
−
 
−
== Training ==
 

Latest revision as of 14:10, 22 August 2024

Vacuum Former.png
Formech.jpg

Make: Formech

Model: 508DT

Serial Number: 2728

Ace: Needed (Makerhub@georgefox.edu).

Location: The Vault


Description

The Formech 508DT Vacuum Former is a plastic molding machine that utilizes heat and a vacuum to stretch heated plastic over a mold. The vacuum former is great for thin plastic molds, although there are some limitations on the shape and size. The max dimensions for the mold are 17”x19” with a depth of 7.3". The max thickness for the plastic sheet is 0.25" Molds can be made from many types of materials. It's fairly common to see molds made from wood. Molds need to have some draft so they can be removed from the plastic.


Here is an example of this piece of equipment being used.

Documentation

Terminology

  • Table- The bed that the mold rests on.
  • Clamp Frame- The metal bars that captivate the plastic sheet as its heated and stretched over the mold.
  • Toggle Clamp Screws-
  • Draft Angle- The wall angle of a mold. This helps in removing the plastic off the mold.

Knowing what the different buttons in the touchscreen operation mean is important in operating the vacuum former. The three primary ones are heat , vacuum , and release . For a full list, refer to the manual.

Vacuum Former User Manual

Vacuum Forming Guide

Training

Operation

The vacuum former can mold up to a 19"x17" square and to a depth of 7.3".

Molds must slant outwardly slightly to ensure that they can be popped out of the plastic after molding is finished.

Demonstration

The demonstration for the vacuum former can use one of the provided demonstration molds or a mold that the trainee brings. The trainee must show that they can set up the vacuum former and mold a part.

Operation

Formech Controls.JPG

Operation

  • Place a mold into the tray and lower it.
  • Mold cannot be concave and must slant outwards slightly or it will not be removable from the plastic.
  • Place plastic into the clamps ensuring it completely covers the white seals.
  • Turn on the heaters and set the temperature. The temperature should be 80-120 degrees Celsius.
  • The heaters should take about 15 minutes to warm up.
  • After 15 minutes roll the heater over the plastic
  • Allow the heater to sit over the plastic for 90 seconds if the plastic is 1.8mm thick or 180 seconds if the plastic is 3.3mm thick.
  • DO NOT OVERHEAT PLASTIC! this will cause the plastic to develop webbing after the vacuum which will ruin the mold.
  • Lift the table.
  • Turn on the vacuum.
  • Let the plastic cool, then hit the release button.
  • Lower the table to remove the plastic.
  • Reset the table.

Safety

  • Parts of the machine can reach over 300 degrees C. Don't touch the heater or heat shield surrounding the heater.
  • Never put your hand in a position it could be pinched by the molding frame.
  • The formed plastic is very hot and sticky. It could stick to you and continue to burn if you touch it.
  • Some types of plastics could give off toxic fumes when heated. Check the SDS before working with materials you are unfamiliar with.

Certification

Complete The Vault - Vacuum Former Module at the link below to gain access to the Vacuum Former. The Maker Hub Canvas course pertains to all facilities and equipment contained in the Maker Hub; simply complete the quizzes for the facilities/equipment you wish to use in the Maker Hub. Please email makerhub@georgefox.edu if you have any questions.

Maker Hub Canvas Course

Troubleshooting

Make sure to put draft on your form to prevent sticking. If the plastic is not hot enough it won't pull down over the form. If the plastic is too hot then it will develop webbing during the vacuum

Maintenance

General maintenance

Specific Maintenance Tasks

Maintenance Procedure Frequency Done By
Inspect As Needed Ace/Tech
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