Dallas Thermoforming Symposium 2010

Sunday, March 7
6:00 pm - 8:00 pm
Registration & Welcome Reception
FUNDED BY OUR SPONSORS
Bring Your Spouse--Plenty of Food & Drink
Great Networking Atmosphere!

Monday, March 8
Registration: 7:00 am - 8:30 am
Symposium: 8:30 am - 5:00 pm
Reception: 6:00 pm - 8:00 pm

Introduction: Robert Browning
Associate Partner, McConnell Co. Inc.

Manufacture of Sheet/Film:
Bill McConnell
President, McConnell Co. Inc.
A. Extrusion
B. Extrusion laminating
C. Co-extrusion
D. Biax

Material Sheet Behavior and Testing for
Processing Excellence & Quality Control
in Thermoforming: Donald Hylton
Associate Partner, McConnell Co. Inc.
A. Polymers
B. Types of thermoforming materials
C. Rheology and viscoelasticity
D. Polymer processing

10:00 am - 10:15 am-Coffee Break

E. Material testing
F. Material testing as a quality control tool
G. Material specifications that should be considered when ordering material

11:45 am - Noon
Special: Texstars' "Bird Strike" Video

Noon - 1:00 pm-Lunch 1:00 pm - 2:00 pm

1:00 pm - 2:00 pm Process Controls
Workshop Improve Capacity of
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 controls
4. Use of trend charts & graphs
5. Data collection to assist in online troubleshooting/diagnostics

2:00 pm - 5:00 pm
Thermoforming Techniques:
Arthur Buckel
Associate Partner, McConnell Co. Inc.
A. Webbing
B. Vacuum forming
C. Pressure forming (using compressed air)
D. Mechanical forming

3:00pm - 3:15 pm-Coffee Break

Modifications of Basic Forming Methods
A. Pre-stretching
B. Snap back-male mold
C. Billow snap-female mold (no plug)
D. Plug assist-female mold
E. Twin sheet thermoforming
F. Slip forming
G. Forming of Composite Sheet

6:00 pm - 8:00 pm-Reception

Tuesday, March 9, 8:30 am - 5:30 pm

8:30 am - 9:25 am
Demonstration New Machine for Testing
Thermoformability of Sheet/Film:
Dr. Amit Dharia, President
Transmit Technology Group LLC

9:45 am -Depart hotel for plant tours:

• Spartech Plastics-large custom
thermoplastics sheet and rolled stock
extrusion. Maintains four extrusion lines
with tri-extrusion capabilities up to 120"
wide.
• Kinro Composites Better Bath Division
Better Bath Division manufactures
thermoformed bathtubs, shower pans,

6:30 pm - 9:00 pm
Dinner Trail Dust Steakhouse

Wednesday, March 10, 8:30 a.m.-3:00 p.m.

Thermoforming Design for Designers of Thin
&Heavy-Gage Products: Robert Browning
Associate Partner; McConnell Co. Inc.
A comprehensive, 3/4-day seminar on
thermoforming product design, and the
development of plastic products using
thermoforming, pressure forming & twin- sheet
thermoforming. Presented by an industrial
designer, with lecture, slides, videos, sketches, samples, real-world case-studies and questions &
Designers & non-designers alike appreciate this hands-on course.
A. Brief background and history of thermoforming
B. Process review - 14 pros & cons of the different forming methods

Noon-1:00 p.m. Lunch

1:00 p.m.-3:00 p.m. Cont. Robert Browning
C. Special case study presentations
D. Registration forming of distortion
printed sheet
E. Thermoforming TPO materials
F. Development of a high-end spa/sauna
G. Videos

3:00 p.m.-3:15 p.m. Coffee Break

3 15 p.m.-355 p.m.-Bill McConnell
Rigidizing Thermoformed Parts
A. Bonded doublers
B. Fiberglass spray-up
C. Spray-up foam
D. Twin-sheet
E. Foam-in-place
F. Composites

4:00 p.m.-5 15 p.m. Infrared Radiation
Heat Imaging Systems-- Hands-on
Demonstrations
Leaders: Paul Ross, VP Solar Products Inc.,
James Earle, Product Manager, Process
Imaging Systems & Gail Segura Regional
Sales Manager, Raytek Corp.
This session discusses the applied theory
& recommended practice for making
temperature measurements using infrared
thermometers. The class will be divided
into small groups so they can be involved
in the demonstrations.

Avoiding the common pitfalls associated
with high temperature, reflections from
heaters, transmitted through thin sheet,
& the challenge of measuring shiny
aluminum will be among the topics
demonstrated. Attendees are welcome
to bring their own infrared hand
thermometers for a free calibration check,
<100° F., on a certified black body
calibration source that will be available.

Thursday, March 11
8:30 a.m.-5:00 p.m.

Heavy & Thin-Gage Sessions Are
Held Concurrently in Different
Rooms Thursday & Friday
Thin Gage Thermoforming
Instructor: Mark Strachan President
Global Thermoforming Technologies
1) Feeding the plastic sheet - This covers
all the methods used to transport the
sheet through the forming, trimming &
stacking processes.
2) Heating the sheet-This covers all the
methods used to heat the continuous
sheet and the benefits of each
10:00 a.m.-10:15 a.m. Coffee Break
3)Forming the sheet - Back to basics –
This session will start with the very
basics of forming & the many techniques
used to form the part.
4) Forming the Part-advanced techniques.
This is a more in-depth look at Forming
Techniques that help with material
distribution & minimizing material usage.

Noon-1:00 p.m. Lunch

5) Punching and Trimming the part –
Basics-This module covers all the
techniques used in the continuous
process to trim the part.
6) Punching and Trimming the part –
Advanced Techniques - this module
takes a closer look at the trim tooling
& how to trim parts more efficiently.

3:00 p.m.-3:15 p.m. Coffee break

7) Stacking the Part-This module
looks at every technique available
to stack and present the thin-gage
parts to the packer.
8) Troubleshooting techniquies

Thursday, March 11
8:30 a.m.-5:00 p.m.

HEAVY GAGE (Cut-Sheet)

Trimming: Robert Browning
A. Safety in Trimming
B. Trimming Tools
C. Route and Drill
D. Saw
E. Die Cut, Sheer, Punch
F. Robotics
G. Deburring

Turnkey Design & Mold Manufacturing
Ken Griep, VP, Portage Casting & Mold Inc.
A. An initial request for a quote
B. Quotation
C. Design & Prototype Part
D. Mold Tryout
E. Production

Tooling for Heavy Gage
Guest 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

Vacuum & Compressed Air Systems
Bill McConnell
• Why fast vacuum needed
• Vacuum pressure measurements
• Surge tanks, vacuum lines &
solenoid sizes, 90° elbows, etc.
• Compressed air systems

Friday Morning, March 12

THIN-GAGE Thermoforming

Instructor: Dr. James Throne, President
Sherwood Technologies Inc.
Characteristics and Challenges
in Thin-Gauge Thermoforming
• Domestic Forming in a Global World
• Thin-Gauge Polymer Materials
• Machine Technologies
• Thin-Gauge Mold Considerations
• Trimming – Whys and Wherefores
• Part Design
• Process Monitoring and Control
Machine Safety in a Litigious Society

Friday Afternoon, March 12

In-Depth Focus on Fundamentals
in Thin-Gauge Thermoforming
• The Whys and Wherefores of Energy Input
• Does Your Sheet Absorb or Transmit Energy? Or Both?
• The Mechanics of Stretching the Sheet
• What Does the Plug Do Mechanically?
• Can Trimming Be Considered as Breaking Plastic?
• How Accurately Can You Trim?

Friday, March 12

Heavy Gage (Cut-Sheet)

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

Troubleshooting by Bill McConnell
1. Pilot Error
2. Mechanical
3. Material
4. Heating
5. Pressure
6. Controls
7. Questions & answers

Heating the Sheet by Bill McConnell
A. Introduction: Processing Temperatures
& Environment
B. Types of Heating,
1. Convection
2. Conduction
3. Radiation