Sheet Fabrication Plet 370

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Sheet FabricationPlet 370

• Matt Eury
• Brian Martonik
• Mike McElhaney

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Objective

• To understand sheet fabrication
• Learn its processability
• Learn the applications

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Outline

• Materials
• Processes
• Equipment
• Secondary operations
• Applications

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Introduction

• Several Sheet fabrication processes
• Many materials used
• Wide range of applications

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Advantages

• Light weight
• Weather Resistance
• Colors
• Good optical qualities
• High impact resistance
• Cost (glass)

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Disadvantages

• Cracking
• Bubbles
• Crazing
• Low Tolerances (Cell Casting)

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Materials

• Acrylic
• Polycarbonate
• Polypropylene
• Polyethylene
• Nylon
• Acetyl

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Processes to Form sheets

• Cell Cast
• Continuous cast
• Extrusion

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Cell Casting

• Poured between sheets of glass
• PVC gasket
• Heat process causes reaction
• Good surface quality and optics
• Low optical distortion

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Cell Casting

• Sizes
• 2 m by 3 m
• Thickness
• 2 to 12 mm

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Continuous Casting

• Poured between polished steel belts
• Belts heat and cool material
• Highest productivity
• High molecular weight
• Harder surfaces
• Isotropic shrinkages

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Continuous Casting

• Sizes
• - varies
• Thickness
• - 1.5 mm

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Extrusion

• Resin pellets melted by extruder
• Shaped by die

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Extrusion

• Sizes
• Up to 4 meters
• Thickness
• .25 to 15 mm

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Equipment

• Auxiliary Equipment
• Blenders
• Screen changers
• Melt Pump
• Static Mixers
• Texture Rolls

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Equipment

• Grinders
• Dryers
• Feedstock

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Secondary Operations

• Cutting
• Decorating
• Drilling
• Forming
• Jointing
• Finishing

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Secondary Operations

• Cutting
• Band Saws
• Circular Saws
• Knife
• Laser Cutting
• Water Jet

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Secondary Operations

• Decorating
• Printing
• Painting
• Stamping
• Decals

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Secondary Operations

• Drilling
• Tapping
• Hole saw
• Drill bits

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Secondary Operations

• Forming
• Thermoforming
• Presses
• Clamps
• Cold forming

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Secondary Operations

• Jointing
• Cementing
• Adhesives
• Dip and soak
• Ultrasonic welding

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Secondary Operations

• Finishing
• Sanding
• Filing
• Ashing
• Polishing

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Desired Properties of sheets

• Sheet properties
• Dimensions
• Surface type
• Orientation
• Contamination

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Desired Properties of sheets

• Toughness
• Moisture content

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Applications of Sheets

• Signs
• Picture frames
• Instrument panels
• Safety shields
• Hot Tubs
• Glass Replacement

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Applications continued
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Conclusion

• Great glass replacement
• Many applications
• Mass production easily accomplished