Thermoforming Research

An easier and faster method to making the windshield.

Guide to Thermoforming (https://formlabs.com/blog/thermoforming/ )

Another Guide (https://www.weetect.com/thermoforming-polycarbonate/ )

Material (https://www.homedepot.com/p/LEXAN-12-in-x-24-in-x-0-093-in-Clear-UV-Stable-Polycarbonate-Sheet-GE-33/202038063 )

Thermoforming Processes

1. Vacuum Forming: This thermoforming process makes use of a vacuum to shape the sheet. First, the plastic sheet is heated to ensure it is flexible. The vacuum forming machine then pulls the air out, forcing the sheet against a mold. The vacuum process is known for its cost-effectiveness and the speed of the manufacturing process.

2. Pressure Forming: The pressure forming process similarly involves the heating of the plastic sheet and utilizing a vacuum to pull air away to force the sheet against a mold. But there’s an extra step. A pressing tool applies pressure once the air is removed to ensure the shaped plastic better maintains its final shape. Pressure forming is used when higher levels of details are required from the thermoforming process.

3. Drape Forming: In drape forming, the heated plastic sheet is draped onto a mandrel designed with specific patterns. The mandrel’s pattern is pressed onto the plastic sheet to form the finished part. The drape forming process is one of the most-affordable thermoforming techniques because limited tooling is required. As the thickness of the material can be maintained, the process doesn’t result in weaknesses in the parts.

   1. https://www.youtube.com/watch?v=6xwp48M2v-8

   2. https://www.youtube.com/watch?v=K8UmJnaWO2s