SPE Dallas Industrial Thermoforming Symposium & Workshop
For Thin & Heavy Gage Thermoforming
MARCH 9-13, 2008
EMBASSY SUITES DALLAS MARKET CENTER,
DALLAS, TEXAS

SUNDAY, MARCH 9, 2008
     Registration & Welcome Reception
     Funded by Our Sponsors
     Bring Your Spouse
     Plenty of Food and Drink
     GREAT NETWORKING ATMOSPHERE
     Please Join Us
   6 p.m. to 8 p.m.

Monday, March 10, 2008
  7 a.m. - 8:30 a.m. Registration
  8:30 a.m. - 5 p.m. Symposium
  6 p.m.-8 p.m. Reception

 :8:30 a.m.- 8:40 a.m. Introduction
    Robert Browning, Associate-Partner
    McConnell Co. Inc.
    [TROUBLESHOOTING QUESTIONS ANY TIME]

  8:40 a.m.-915 a.m.
    Manufacture of Sheet/Film
    Speaker: Bill McConnell, President
    McConnell Co. Inc.

      A. Extrusion
      B. Extrusion Laminating
      C. Coextrusion
      D. Biax
      E. Calendering

  9:15 a.m.-11:40 a.m.
    Material Sheet Behavior and Testing for Processing
    Excellence and Quality Control in Thermoforming
    Speaker: Don Hylton, Associate-Partner, McConnell Co., Inc.
.
      A. Polymers
          1. Polymer Chemistry
              ? Effect on Processing
          2. Polymer Morphology
              ? Why it?s Important in Processing
      B. Types of Thermoforming Materials
          1. Amorphous Materials
          2. Crystalline Materials
          3. TPO Elastomer Materials
              ? How Resin is Manufactured
              ? TPO Rheology
          4. Other Elastomers
              ? TPE, TPU, etc
      C. Rheology and Viscoelasticity
          1. What is Viscoelasticity?
          2. Role of Viscoelasticity
          3. Effect on Processing
      D. Polymer Processing
          1. Principle of Accountability
          2. Process Flow Diagram
          3. Material Behavior in Processing
          4. Bulk Properties
          5. Heat Histories
          6. Part Performance

  10:00 am ? 10:15 am Coffee Break

      E. Material Testing
          1. ASTM Methods and Standards
          2. Tests for Formability
          3. Applicability
      F. Material Testing as a Quality Control Tool
          1. Specifications
          2. Laboratory QA/QC
      G. Material Specifications that Should be Considered when Ordering Material
          1. Specs for Cut-Sheet (Heavy Gage)
          2. Specs for Thin Gage (Roll-Fed)

  11:45 am ? 12:00 Noon
    Special: Texstars? "Bird Strike Video"

  12:00 Noon-Lunch

  1:00 p.m. - 2:00 p.m.
    Process Controls Workshop
    "Improved Production Capacity of Your
    Equipment by Use of Modernized Controls"
    Guest Speaker: Michelle Curenton, Product Manager, Weco International, Inc.

      A. Modernize Controls
          1. Develop product codes for process variables
          2 How to tune controls to automatically adjust set points for closed-loop control algorithms
             (including platen movement,  gage/profile,temperatures when vacuum and/or compressed
             air is applied)
          3. How to improve quality & consistency with improved ontrols
          4. Use of trend charts/graphs & also for a alarming
          5. Data collection to assist in on-line troubleshooting/diagnostics

  2:00 p.m.-5:00 pm
    Thermoforming Techniques
    Speaker: Arthur Buckel, Associate-Partner
    McConnell Co. Inc.

      A. Webbing
      B. Vacuum Forming
          1. Why Fast Vacuum Needed
          2. Vacuum Pressure Measurements
          3. Surge Tanks, Vacuum Lines, Solenoid Sizes, 90° Elbows, etc.
      C. Pressure Forming (Use of Compressed Air)
          1. Free Pressure
          2. Pressure Plate or Box
          3. Pressure Box ? Roll Fed Thin Gage
      D. Mechanical Forming
          1. Stretch Forming
          2. Ridge Forming
          3. Strip Heating

  3: 00 p.m. -3:15 p.m. Coffee Break

    Modifications of Basic Forming Methods
      A. Pre-stretching
      B. Snap Back?Male Mold
          1. Billow Snap Back?Male Mold
          2. Billow Snap Back (with a pressure chamber)
      C. Billow Snap?Female Mold (No Plug)
      D. Plug Assist?Female Mold
          1.  Plug Assist
          2. Billow Plug Assist?Female Mold
      E. Twin Sheet Thermoforming
          1. Process
          2. Molds
          3. Twin Sheet Thermoforming
      F. Slip Forming
          1. Loose Clamping Frame
          2. Clamping Two Sides of Sheet
          3. Use of Multiple Vacuum Zones
      G. Forming of Composite Thermoplastic Sheet
          1. Material Properties Applications
          2. Mold Designs
          3. Sheet Heating & Forming Techniques
          4. Trimming

  5:00 p.m. Adjourn

  6:00 pm ? 8:00 pm Welcome Reception
    Embassy Suites Dallas Market Center
    Funded By Our Sponsors
    Plenty of Food & Drink!
    GREAT NETWORKING ATMOSPHERE

TUESDAY, MARCH 11, 2008
  8:30 a.m.-5:30 p.m.

  8:30 a.m.-9:30 a.m.   Demonstration New Machine For Testing Thermoformability of Sheet/Film
  Dr. Amit Dharia, President
  Transmit Technology Group, LLC

  9:45 a.m. - Noon
    Plant Tour: Precision Formed Plastics.

  12:00 Noon-Lunch

  12:45 pm (approximate)
    Depart hotel for plant tours
  12:45 p.m.-5:30 p.m:
    1.  Spartech Plastics, Custom Sheet Extrusion Plant
    2. Kinro Composites Better Bath Division, A Large Custom Thermoforming Plant With 9 Large
        Rotary Thermoformers Including a 3 Station 10 foot x 25 foot Platen Size.

  Return to hotel by 5:30 pm
  6:30 pm ? 9:00 pm Dinner
      Trail Dust Steakhouse
      ?Dress in your best cowboy duds!?
      YOU ARE INVITED TO BRING YOUR SPOUSE AS OUR GUEST
      Funded By Our Sponsors
      Transportation is provided for the plant tours and dinner

WEDNESDAY, MARCH 12, 2008
  8:30 am ? 5:15 pm

  The heavy gage & thin gage sessions are held concurrently in different rooms on Wednesday

THIN GAGE SESSION   8:30 a.m.-5 15 p.m.

  [TROUBLESHOOTING QUESTIONS ANY TIME]

    Characteristics of and Challenges in Thin-Gauge Thermoforming
    Jim Throne, Consultant
    Sherwood Technologies, Inc.

        Domestic Forming in a Global World
            • Advantages and Risks in Following Your Customer Overseas Thin-Gage Materials
            • Conventional Polymers — Anything New?
            • APET and CPET
            • OPS
            • Foams
            • Biopolymers (PLA and others)
            • Nanopolymers?
        Machine Technologies
            • Conventional Machines
            • Machines for the Clean Room
            • Contact Forming
            • Form, Fill and Seal
            • Extrusion-Thermoforming Lines
            • Wheel Machines
            • Tilting Platen Machines
            • Used v. Rebuilt v. New

  Noon - 1:00 p.m. Lunch

        Mold Considerations
            • Prototyping?
            • Grids
            • Plugs
        Trimming — Whys and Wherefores
            • In-Press, In-Machine, In-Line —Which?
            • Flat-Bed v. Canopy
            • Tandem Trimming
            • Trim Line Registration Issues
        Part Design
            • Wall Thickness Control/Prediction
            • Rim Rolling
            • Detents and Other Closures

        Process Monitoring and Control

        Machine Safety in a Litigious Society
            • Maintenance — Scheduled and Crisis
            • Training and Retraining
            • "Lock It, Pocket It"
  5:15 p.m. Adjourn

HEAVY GAGE (CUT-SHEET) SESSION
[TROUBLESHOOTING QUESTIONS ANY TIME]

  8:30 a.m. ? 10:00 a.m.
Thermoforming Optically Clear & Class A Finished Parts
Guest Speaker-Jim Irion, VP Engineering, Texstars, Inc.

1. Material types & processes
2. Forming optically clear canopies, windshields, etc.
3. Secondary treatments
4. Inspection methods

  10:00 a.m. - 10:15 a.m. Coffee Break

  10:15 a.m. ? 12:00 Noon
  Trimming Heavy Gage
  Guest Speaker: Robert Browning

  A. Safety in Trimming
  B. Trimming Tools
  C. Route and Drill
  D. Saw
  E. Die Cut, Sheer, Punch
    1. Steel Rule Dies
    2. Matched Punch Dies
    3. In-mold Dies
    4. Heated Dies
  F. Robotics
    1. Routing
    2. High Pressure Waterjet
    3. Laser
  G. Deburring

  12:00 Noon - 1:00 p.m. Lunch

  1:00 p.m.-1:30 p.m
  Rigidizing Thermoformed Parts
  Speaker: Bill McConnell

  1. Bonded Doublers
  2. Fiber Glass Spray-up
  3. Twin Sheet
  4. Foam-in-Place
  5. Spray-up Foam

  Tooling for Heavy Gage
  Guest Speaker: Robert Browning
  1:30 p.m. - 3:00 p.m.
  Speaker: Robert Browning

    1. Male versus Female
    2. Construction
    3. Vacuum Holes, Races, Slots
    4. Vacuum Zones & Moats
    5. Break-Aways & Undercuts
    6. Temperature Control
    7. Mechanical Helpers
    8. Spec Check List for Mold Design

  3:00 p.m. - 3:15 p.m. Coffee Break

  3:15 p.m. - 5:15 PM
  Turnkey Design & Mold Manufacturing
  Guest Speaker: Ken Griep, Vice President, Portage Casting & Mold, Inc.

    1. An Initial Request for Quote
    2. Quotation
    3. Design and Prototype Part
    4. Mold Tryout
    5. Production

  5:15 p.m. Adjourn

THURSDAY, MARCH 13, 2008
JOINT THIN AND HEAVY GAGE SYMPOSIUM
[TROUBLESHOOTING QUESTIONS ANY TIME]
  8:30 a.m. - 5:30 p.m.

  8:30 a.m. - 10:00 a.m.
  Heating the Sheet
  Speaker: Bill McConnell

  A. Introduction
    1. Processing  Temperatures &  Environment
  B. Types of Heating
    1. Convection
      a. Preheat Oven for Roll Fed Machines
      b. Cell Cast Acrylic Ovens
      c. Heating of Heavy Gage Solid & Foam Sheet
      d. Prototype Forming
      e. Drying of Hydroscopic Sheet Such as ABS, PC, Etc.
    2. Conduction
      a. Conduction Heating  Plates
      b. Form-Fill-Seal Thermoforming
      c. Heat-Form-Trim in Same Station  (GN, Kirkoff, Etc. machines)
    3. Electromagnetic Radiation
      a. Coiled Resistance Wire
      b. Metal Tubular Heaters
      c. Flat Panel Heaters
      d. Ceramic
      e. Flat Aluminum
      f. Flat Steel
      g. Flat Quartz
      h. Glass (Such As Pyrex, etc.)
      i. Woven Quartz Cloth
      j. Quartz Tubes
      k. Gas Heaters
      l. Catalytic Heater Panels
      m. Open Flame Gas Heaters
      n. Halogen

  10:00 a.m. - 10:20 a.m. Coffee Break

  10:20 a.m. ? noon
  Infrared Radiation Heat Imaging Systems
  "Hands-On" Demonstrations
  Joint Demonstration Leaders:
  Paul Ross, VP Solar Products, Inc.
  James Earle, Product Manager, Process Imaging Systems, Raytek Corp.
  Gail Segura, Central Regional Sales Manager, Raytek Corp.

  This session will discuss the applied theory and recommended practice for making temperature
  measurements  using infrared thermometers. Attendees will divide into three groups for "hands-on"
  demonstrations with selected instruments. Participants may bring their own infrared hand thermometers
  for use during this session. A free calibration check, <1000°F, on a certified blackbody calibration source
  will be made available for participant's infrared thermometers. Avoiding the common pitfalls associated
  with high temperature reflections from heaters, transmitted radiation through thin sheet, and the
  challenge of measuring shiny metal molds will be among the topics demonstrated.

  Noon ? Lunch 12:00 - 1:00 p.m.

  1:00 p.m. - 5:15 p.m.
  Thermoforming Design for Designers of Thin and Heavy Gage Products
  Guest Speaker: Robert Browning
  [TROUBLESHOOTING QUESTIONS ANY TIME]

  Purpose & Overview
  This is a comprehensive one/half-day seminar on thermoforming product design, and the development
  of plastic products using thermoforming, pressure forming and twin-sheet thermoforming. This intensive,
  fast paced seminar will help to provide a better understanding of thermoforming design, its limitations and
  advantages. Both designers and non-designers will appreciate this straightforward, hands-on course, in
  expanding their knowledge and insight into today?s fast pace and competitive design world.

  The program is presented by an Industrial Designer, with lecture, slides, videos, sketches, samples, real
  world case studies and questions and answers. Attendees are encouraged to bring questions and their
  design problems for discussion.

  Additional topics include forming polycarbonates on composite molds; TPO materials and forming
  techniques; distortion printing & thermoforming; forming parts for the automotive and airline industry;
  all topics explained with Case Studies.

  A. Brief Background and History of Thermoforming
  B. Process Review ? Pro?s & Con?s of the Different Forming Methods
    1. Materials and Properties
      a. Thermoset vs. Thermoplastics
      b. Molding & Trimming
    2. Tooling/Mold Design and Considerations
      a. Undercuts
      b. Male or Female Molds
      c. Articulating Molds
      d. Plug Assist
    3. Tooling Checklist Review
    4. Prototypes & Samples
      a. Methods
      b. Pro?s & Cons
    5. Creative Design Alternatives
      a. Thermoforming
      b. Pressure Forming
      c. Twin-sheet Forming
    6. Mechanical Considerations
      a. How is the Part Used
      b. Ribs
      c. Gussets
      d. Tolerances
      e. Material Thinning & Control
      f. Molded-in Inserts & Hardware
    7. Environmental Considerations
      a. Environment Exposure to UV & Weather
    8. Appearances, Finishes and Decorating
      a. Style
      b. Shape
      c. Color
      d. Texturing
      e. Surface Finish
      f. Molded-in Details
    9. Design Limitations in Thermoforming
    10. Do?s and Don?ts in Design
    11. When to Look at Other Processes
    12. Product Development Management
      a. From Design Concept to Production
      b. Case Studies
    13. Distortion Printing & Thermoforming
    14. Troubleshooting