Difference between revisions of "Belovac Vacuum Forming Machine"

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===Materials for Buck/Form===
 
===Materials for Buck/Form===
These are an exmaple of some materials that can be used for molding
+
These are an exmaple of some materials that can be used for molding. The material needs to be heat resistant. It should also have a flat base for stability on the platform.
  
* [https://www.amazon.com/SELECTION-5lb-Plaster-of-Paris/dp/B077MD57S3/ 5lb Plaster of Paris]
+
* [https://www.amazon.com/SELECTION-5lb-Plaster-of-Paris/dp/B077MD57S3/ Plaster of Paris]
 
* [https://www.alumilite.com/store/p/1055-Vac-Master-50.aspx Vac-Master Resin with Aluminum]
 
* [https://www.alumilite.com/store/p/1055-Vac-Master-50.aspx Vac-Master Resin with Aluminum]
 
* MDF ( Shaped on CNC or pre-shaped )
 
* MDF ( Shaped on CNC or pre-shaped )
 +
* Aluminum/Steel Part
  
 
===Materials for Forming===
 
===Materials for Forming===
High Impact Polystyrene (HIPS)
+
Information on safe thermoformable materials in sheets.
* [https://www.amazon.com/gp/product/B017S4BEIM/ref=ox_sc_saved_title_1?smid=A1FWWCVO9POVQF&psc=1 12inx12in HIPS sheets]
 
  
 
Material Selection Guide - https://www.toolcraft.co.uk/vacuum-forming/advice/vacuum-forming-help-material-selection-guide.htm
 
Material Selection Guide - https://www.toolcraft.co.uk/vacuum-forming/advice/vacuum-forming-help-material-selection-guide.htm
 +
 +
'''Incomplete List'''
 +
* High Impact Polystyrene (HIPS)
 +
** [https://www.amazon.com/gp/product/B017S4BEIM/ Example 12inx12in HIPS sheets]
 +
* Acrylonitrile Butadiene Styrene (ABS)
 +
** [https://www.amazon.com/ABS-Plastic-Sheet-Thick-Thickness/dp/B004WP24XU/ Example 12inx12in ABS sheets]
 +
  
  
 
== Tips & tricks ==
 
== Tips & tricks ==
 +
 +
 +
=== Creating an appropriate Buck/Mold ===
 +
* Part should have a flat base
 +
* No overhangs
 +
* Pay attention to draft angles
 +
  
 
===Troubleshooting===
 
===Troubleshooting===

Revision as of 12:53, 26 February 2019


Belovac Vacuum Forming Machine
[[file:Belovac Vacuum Former Main.jpg|frameless]]
Owner/Loaner PS:One
Make/Model Belovac BV E-Class
Arrival Date 2018
Usability yes
Contact User:Rtystgeeke
Where Hot Metals
Authorization Needed yes
Hackable no
Estimated Value tbd
Host Area Hot Metals


Belovac Vacuum Forming Machine Area: Hot Metals https://wiki.pumpingstationone.org/Belovac_Vacuum_Forming_Machine



Overview

This vacuum forming machine has been donated by SAIC and is currently installed in Hot Metals area. A Danger Committee was formed and the machine is ready for member use pending authorization.

How to Get Authorized

Authorization for this machine is on demand. Please send a request on the Google Group to see when an Authorizer (below) is available.

Please review the information on this page, in particular the Safety section.

Please bring your own materials, as there is no guarantee there will be any available. A few sheets of thin 12in x 12in ABS/HIPS would be ideal.

Current Status

This machine is working but requires maintenance and improvements.

Usage

Vacuum Forming, is a type of Thermoforming,which is the process of heating a plastic sheet and stretching it over a mold. As the plastic cools, it hardens, permanently retaining that shape.

This device can handle any thermoformable plastic up to 3/8" thick.

Depending on which platen/frame that is used, the machine can accept 3 sizes of plastic sheets. 12inx12in, 24inx24in and 24inx48in. The usable area in those sheets after being secured in the frames being 9.25inx9.25in, 21inx21in, or 21.5inx45.5in.

The "buck," or form, may be any sturdy shape that can tolerate a bit of heat. Wood, MDF, metal, and polyester resin work well. Avoid shapes with hollows underneath because they have a tendency to collapse. Shapes with undercuts, or shapes taller than they are wide, will be very difficult to remove from the formed plastic. Paint, shellac, or epoxy resin can cause the hot plastic to stick.

The oven must be used only for vacuum forming. Please do not attempt to use this machine to dry materials or anything other than its intended purpose.

Other related tools/skills:

  • ShopBot Auth - to create molds out of MDF with the CNC.
  • Woodshop Auth
    • Bandsaw - To cut flashing (excess material) from thick finished parts with Vertical Bandsaw.
    • Panel Saw - to cut sheets of plastic to correct frame size.
  • 3D Printer Auth
    • to create mold to cast plaster buck

Usage Steps

The following instructions are an initial release of how to run the machine.

Steps Diagram/Picture
  1. Insert sheet of material into Frame
  2. Close the frame latch to the secure the material
  3. Secure Mold to Vacuum table
  4. Check seals around material and mold
  1. Turn on Wall Power
Bvf main power.jpg
  1. Turn on Machine Power
Bvf machine power.jpg
  1. Select Number of Heating Elements
  2. Select Duty Cycle
  1. Connect Pneumatic Hose. It can be borrowed from the CNC Plasma Cutter, if not in use.
  2. Turn on Heating Element
Bvf control panel.jpeg
  1. Move material frame into heater
  2. Close Vacuum Valve
  3. Turn on pump, to begin to build vacuum
Bvf control panel.jpeg
  1. Visually check if heating element is on and if material is warming
  2. Visually check if material is sagging and ready

Bvf heat 1.jpg Bvf heat 2.jpg

  1. Pull Material frame forward
  2. Inspect Plastic is ready
  3. push level to raise vacuum bed
  4. Open Vacuum Valve
  5. Monitor pull of material over mold
  1. Turn off Vacuum
  2. Turn off Heater
  3. Disconnect pneumatic hose. Return to CNC Plasma Cutter.


Safety

The Vacuum Former has an oven surface for heating and softening the plastic. It is made of multiple panels (total 6) infared radiant heating elements, draws a total 80,000 watts (top and bottom), and reaches full operating temperature depending on Active heating time set on the timer.

The most likely source of problems would be for someone to leave the plastic under the heater for way too long and set it on fire. To help avoid this error, we are only using the center top panel for heating. Ignoring safety protocal is cause for revoking authorization.

Fumes from most plastics are not expected to be significant when the machine is used properly (i.e., nothing is on fire). If fumes do turn out to be a concern, the machine can be retrofitted with a fume hood. Then existing exhaust duct for the Forge could be used.


Warnings

  • HOT SURFACE - Metal Frame holding material and handles will be hot. Wear Gloves during operation. Hot sm.png
  • Fire sm.png FIRE - Material may catch fire while heater is left on. Do not leave unattended.
  • CRUSHING - Make certain there is nothing obstructing the platform, before pulling the pneumatic lever raising the mold to frame. Clear Obsctructions. Crush sm.png
  • Shock sm.png ELECTRIC SHOCK - High Voltage machinery (3 Phase Power) required to run motors and heating elements. Make certain cabling is secure and undamaged before operating. Check Cabling.


Machine Information

Company page: http://www.belovac.com/manual_deep_draw.html

Training Resources

Videos


Materials

NOTE: Materials are not provided. Member must bring their own materials for use with this machine. Please consult material selection guide to select appropriate plastic sheets for thermoforming.

Example Materials for use with the machine below:

Materials for Buck/Form

These are an exmaple of some materials that can be used for molding. The material needs to be heat resistant. It should also have a flat base for stability on the platform.

Materials for Forming

Information on safe thermoformable materials in sheets.

Material Selection Guide - https://www.toolcraft.co.uk/vacuum-forming/advice/vacuum-forming-help-material-selection-guide.htm

Incomplete List


Tips & tricks

Creating an appropriate Buck/Mold

  • Part should have a flat base
  • No overhangs
  • Pay attention to draft angles


Troubleshooting

How long does it take to heat the plastic sheet?

  • This depends on which material and thickness is specified.

How do I know when the plastic is ready to form?

  • Generally speaking it is necessary with any new material to establish the correct heating cycle. Plastic is ready to form when it becomes soft and pliable especially nearer to the clamping frame. This is known as glass transition temperature (Tg). Once you have established the time you can set the heater timer for accurate and repeated heating cycles.

Why is the plastic webbing on the mold?

  • Material is too hot.
  • Insufficient vacuum.
  • Excess of material. Use reducing windows.
  • Poor mold design.

Why can't I achieve good definition on the finished part?

  • Material too cold
  • Mold too cold.
  • Insufficient vacuum.
  • Insufficient vacuum holes in the mold

Why Is the plastic thinning over the mold when formed?

  • Sheet cooled whilst forming.
  • Mold design with insufficient draft angles.
  • Too thin plastic gauge.
  • Pre-stretch required.
  • Plug assist required.

Why does the plastic bubble and pit when heated?

  • Material is Hygroscopic which needs to be pre-dried prior to forming.
  • Overheating.
  • Mold or plastic sheet too dusty

Why does the plastic stick to the mould when I try to release?

  • Mold not fixed on baseboard.
  • Insufficient draft.
  • Mold undercuts.

Maintenance and Repairs

  • Get Running - DONE
  • Add equipment sticker to machine for wiki info
  • Fix platen/frame rubber seals
  • Build basic test mold for demos and training. (PS1 Logo or Mask)
  • Move Gauge before valve to measure vacuum
  • Larger Vacuum Tank
  • More powerful Vacuum Pump
  • Temperature Monitoring
  • Attach Control Panel to machine

Authorizers

Member Authorization Times
Andrew Camardella By Request

How to Become an Authorizer

Get an ok from the area host. Successfully run an authorization supervised by an authorizer.

List of Currently Authorized Users

Authorized Member Authorized By Date
Andrew Camardella Self Sometime
Dan Sharp Andrew Camardella 1/12/19
Greg "Nerobro" Teiber Andrew Camardella 1/12/19
Adam Stein Andrew Camardella 1/12/19
Mariano Muñoz Andrew Camardella 11/22/18