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Line 148: − + − + − + − + − + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + − # Turn off Vacuum+ − + − + − − − + − + − + − * '''HOT SURFACE''' - Metal Frame holding material and handles will be hot. '''Wear Gloves''' during operation. [[File:Hot sm.png|150px]]+ − * [[File:Fire sm.png|150px]] '''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'''. [[File:Crush sm.png|150px]]+ − * [[File:Shock sm.png|150px]] '''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'''.+ − + + + + + + + + + + + + + + + + + Line 136:
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Line 350: − + − − == List of Currently Authorized Users == − {| class="wikitable" border="2" − ! 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 − |} − − [[Category: Hot Metals]]
Belovac Vacuum Forming Machine (view source)
Revision as of 10:08, 7 January 2021
, 10:08, 7 January 2021no edit summary
|contact = [[User:Rtystgeeke]]
|contact = [[User:Rtystgeeke]]
|value = tbd
|value = tbd
|image = [[File:Belovac Vacuum Former Main.jpg|300px]]
|image = Belovac_Vacuum_Former_Main.jpg|300px
}}
}}
=== How to Get Authorized ===
=== 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.
'''Authorization for this machine is on demand and viral'''. Please make a request on the Google Group to see when an Authorized member (below) is available and coordinate an authorization.
Please review the information on this page, in particular the Safety section.
Please review the information on this page, in particular the Safety section before meeting.
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.
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 ===
=== Current Status ===
This machine is working but requires maintenance and improvements.
This machine is working but requires maintenance and improvements (see list below).
== Vacuum Forming Process ==
== Vacuum Forming Process ==
* ShopBot Auth - to create molds out of MDF with the CNC.
* ShopBot Auth - to create molds out of MDF with the CNC.
* Woodshop Auth
* Woodshop Auth
** [https://wiki.pumpingstationone.org/Rockwell_14_inch_bandsaw Bandsaw] - To cut flashing (excess material) from thick finished parts with Vertical Bandsaw.
** [https://wiki.pumpingstationone.org/Rockwell_14_inch_bandsaw Band saw] - To cut flashing (excess material) from thick finished parts with Vertical Band saw.
** [https://wiki.pumpingstationone.org/Porter_Cable_Panel_Saw Panel Saw] - to cut sheets of plastic to correct frame size.
** [https://wiki.pumpingstationone.org/Porter_Cable_Panel_Saw Panel Saw] - to cut sheets of plastic to correct frame size.
* 3D Printer Auth
* 3D Printer Auth
===Usage Steps===
===Usage Steps===
The process consists essentially of inserting a thermoplastic sheet in a cold state into the clamp area, heating it to the desired temperature either with the heater, and then raising the mould from below. The trapped air is evacuated with the assistance of a vacuum system. Once cooled, the platform is lowered to release the formed plastic part from the mould.
The process consists essentially of inserting a thermoplastic sheet in a cold state into the clamp area, heating it to the desired temperature with the heating elements, and then raising the buck/form/mould from below. The trapped air is evacuated with the assistance of a vacuum system. Once cooled, the platform is lowered to release the formed plastic part from the buck/form/mould.
The following instructions are an initial release of how to run the machine. Please provide feedback or feel free to make edits.
The following instructions are an initial release of how to run the machine.
Please review '''Safety''' section below the Instructions.
Please provide feedback or feel free to make edits.
{| class="wikitable" border="2"
{| class="wikitable" border="2"
|-
|-
|
|
''' Power On Procedure '''
# Turn on Wall Power
# Turn on Wall Power
Note: Check that plug below panel is connected. It may be disconnected.
|[[File:Bvf main power.jpg|300px]]
|[[File:Bvf main power.jpg|300px]]
|-
|-
|-
|-
|
|
# Select Number of Heating Elements
# Push bar forward to close frame clamps and secure overall frame.
# Select Duty Cycle
Note: Do not use as handle when pushing/pulling frame into position.
|[[File:Bvf_frame_clamps.jpg|300px]]
|-
|
* Select desired Valve configuration on bed/platen/platform.
# Both Valves closed for 12inx12in frame
# Left Valve Closed and Right Valve Open for 24inx24in frame
# Both Valves Open for 24inx48in frame
|[[File:Bvf_platform_valves.jpg|300px]]
|-
|
# Connect Pneumatic Hose. This allows one to raise/lower the platform.
Note: It can be borrowed from the CNC Plasma Cutter, if not in use.
Note: The main valve with yellow handle, behind the CNC Plasma cutter, above the large tank, may be closed if there is no air.
|
[[File:Bvf_pnuematic_hose_01.jpg|300px]]
[[File:Bvf_pnuematic_hose_02.jpg|300px]]
|-
|
# Secure Buck/Form/Mould to Vacuum table. If it is heavy enough and does not stick, it may not need to be secured.
Note: it is recommended to have the mold be a bit taller than desired part, to allow space for cut separation.
# Check seals around material and mold.
Note: If material is not thick enough, it may slip out of the frame.
# Raise part way to make certain mold lines up with frame.
Note: It is a 3 position pneumatic valve. Up position raises platform. Center position, holds platform at current position. Down position, lowers platform.
|-
|
# Insert sheet of material into Frame.
|[[File:Bvf_frame_open_small.jpg|300px]]
|-
|
# Close the frame latch to the secure the material.
|[[File:Bvf_frame_latch_small.jpg|310px]]
|-
|-
|
|
# Connect Pneumatic Hose. It can be borrowed from the CNC Plasma Cutter, if not in use.
# Select Number of Heating Elements to turn on.
# Turn on Heating Element
Note: currently only using middle/center
|[[File:Bvf_heater_select.jpg|300px]]
|-
|
# Select '''On''' Percentage Duty Cycle (0%-100%) for Heating Elements. It is on a 15 second timer.
Note: This controls the cycle time of the heating elements being On (at dial), then Off (top of timer).
|[[File:Bvf_heat_duty_cycle.jpg|300px]]
|-
|
# Turn on Heating Element
Note: You will see the Timer begin to rotate counter clockwise and audibly hear the contactors/relays energize.
|[[File:Bvf control panel.jpeg|300px]]
|[[File:Bvf control panel.jpeg|300px]]
|-
|-
|
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# Move material frame into heater
# Move material frame into heater by pushing on front of slide.
# Close Vacuum Valve
Note: do not use frame clamp bar as handle.
# Turn on pump, to begin to build vacuum
|[[File:Bvf_heat_1.jpg|300px]]
|[[File:Bvf control panel.jpeg|300px]]
|-
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# Close Vacuum Valve (facing valve, rotate clockwise, with handle position pointing to the left at final position.)
# Turn on pump, to begin to build vacuum.
|
[[File:Bvf_vacuum_valve.jpg|300px]]
[[File:Bvf control panel.jpeg|300px]]
|-
|-
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# Visually check if heating element is on and if material is warming
# Visually check if heating element is on and if material is warming
# Visually check if material is sagging and ready
Note: The heating elements will visibly glow red.
# Visually check if material is sagging and ready.
Note: It will visibly sag and look like a dome.
|
|
[[File:Bvf heat 1.jpg|300px]]
[[File:Bvf heat 1.jpg|300px]]
|-
|-
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# Pull Material frame forward
# Pull Material frame forward (towards front/away from heaters) completely forward until it stops.
# Inspect Plastic is ready
Note: Do not pull on frame clamp bar. It will open all 3 clamps if pulled on.
# push level to raise vacuum bed
# Inspect Plastic is ready (sufficiently heated/soft).
# Open Vacuum Valve
|[[File:Bvf_frame_forward.jpg|300px]]
# Monitor pull of material over mold
|-
|
# Make certain area is clear before raising bed/platen/platform.
# push lever up to raise vacuum bed/platen/platform.
|
[[File:Bvf_platform.jpg|300px]]
[[File:Bvf_platform_lever.jpg|300px]]
|-
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# Open Vacuum Valve (rotate counter clockwise, with handle position pointing down at final position).
# You should see the plastic part quickly take the shape of the mold.
# Monitor pull of material over mold.
|
[[File:Bvf_vacuum_valve.jpg|300px]]
[[File:Bvf_vacuum_pull.jpg|300px]]
|-
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# Close Vacuum Valve to Turn off Vacuum, when part is ready.
# Allow part sufficient time to cool, before separation. This time frame is dependent on the thickness of your material.
# Push bed/platen/platform lever down to lower platform and pull mold away from formed part.
|
[[File:Bvf_vacuum_valve.jpg|300px]]
[[File:Bvf_platform_lever.jpg|300px]]
|-
|
'''Shutdown Procedure'''
# On Control panel, Turn Heater switch to Off position.
# On Control panel, Turn Vacuum switch to Off position.
# Open Vacuum Valve (rotate counter clockwise, with handle pointing down), to release any remaining vacuum in the tank.
# Push platform lever down, to release air pressure from pneumatic hose. (Hose will momentarily whip around at next step if air is not released)
# Disconnect pneumatic hose. Return to CNC Plasma Cutter.
# Turn off machine power.
# Turn off Main Wall power.
# Make certain material frames are closed and not left open. (where they can snap shut accidentally)
|
[[File:Bvf machine power.jpg|300px]]
[[File:Bvf main power.jpg|300px]]
|-
|-
|
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'''Cleanup Procedure'''
# Turn off Heater
# Cleanup any unused material or scrap.
# Disconnect pneumatic hose. Return to CNC Plasma Cutter.
# Throw away failed part pulls in dumpster. '''Do not leave in Hot Metals area.'''
|}
|}
==Safety==
==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 Vacuum Former has an oven surface for heating and softening the plastic. It is made of multiple panels (total 6) infrared 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.
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. '''Warning:''' Ignoring safety protocol 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.
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 connected to the existing exhaust duct for the Forge. To improve air quality, turn on the forge exhaust and open the front door by the plasma cutter computer.
===Warnings===
===Warnings===
{| class="wikitable" border="2"
! Danger/Warning
! Description
! Mitigation
|-
|[[File:Hot sm.png|150px]]
|'''HOT SURFACE''' - Metal Frame holding material and handles will be hot.
|'''Wear Gloves''' during operation
|-
|[[File:Fire sm.png|150px]]
|'''FIRE''' - Material may catch fire while heater is left on.
|'''DO NOT Leave Unattended'''
|-
|[[File:Crush sm.png|150px]]
|'''CRUSHING''' - Make certain there is nothing obstructing the platform, before pulling the pneumatic lever raising the mold to frame. Make certain steel material frames are not left open. They can fall forward, quickly snapping shut.
|'''Clear All Obstructions'''
|-
|[[File:Shock sm.png|150px]]
|'''ELECTRIC SHOCK''' - High Voltage machinery (3 Phase Power) required to run motors and heating elements. Visually check that power cabling is secure, grounded and undamaged before operating and touching metal enclosure.
|'''Check Cabling'''
|}
==Machine Information==
==Machine Information==
=== Videos ===
=== Videos ===
* [https://www.youtube.com/watch?v=jVvMgkn8st8 About Vacuum Forming Process]
* [https://www.youtube.com/watch?v=jVvMgkn8st8 About Vacuum Forming Process]
* [https://www.youtube.com/watch?v=r94oDj7CMRw Makerbot Post Processing: Vacuum Forming]
* [https://www.youtube.com/watch?v=bD10sMJJbf8 Overview of newer model]
* [https://www.youtube.com/watch?v=bD10sMJJbf8 Overview of newer model]
* [https://www.youtube.com/watch?v=fTFnsG814Pc Custom Vacuum Box creation]
* [https://www.youtube.com/watch?v=fTFnsG814Pc Custom Vacuum Box creation]
===Materials for Buck/Form===
===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.
These are an example 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/ 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 Form ( Shaped by Shopbot CNC or purchased pre-shaped )
* Aluminum/Steel Part
* Aluminum/Steel Part
===Materials for Forming===
===Materials for Forming===
Information on safe thermoformable materials in sheets.
Information on safe thermo-formable materials in 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
* Acrylonitrile Butadiene Styrene (ABS)
* Acrylonitrile Butadiene Styrene (ABS)
** [https://www.amazon.com/ABS-Plastic-Sheet-Thick-Thickness/dp/B004WP24XU/ Example 12inx12in ABS sheets]
** [https://www.amazon.com/ABS-Plastic-Sheet-Thick-Thickness/dp/B004WP24XU/ Example 12inx12in ABS sheets]
'''Plastics Distributors''' taken from [http://www.tk560.com/vactable4.html tk560.com]
Order full sheets 4'x8' and cut to desired size with panel saw.
*[http://www.professionalplastics.com/cgi-bin/pp.pl?pgm=co_disp&func=displ&strfnbr=3&prrfnbr=85378&sesent=0,0 ProfessionalPlastics.com]
*[http://www.indplastic.com/index.cfm?id=138046&fuseaction=browse&pageid=142 IndPlastic.com]
*[http://www.usplastic.com/catalog/default.asp USPlastic.com]
===Troubleshooting===
=== Trimming Part ===
* Depending on the thickness of the material, a band saw or box cuter can be used to trim excess flashing from the final part.
=== Troubleshooting ===
How long does it take to heat the plastic sheet?
How long does it take to heat the plastic sheet?
* Fix platen/frame rubber seals
* Fix platen/frame rubber seals
* Build basic test mold for demos and training. (PS1 Logo or Mask)
* Build basic test mold for demos and training. (PS1 Logo or Mask)
* Move Gauge before valve to measure vacuum
* Move vacuum gauge to before the valve, to measures the vacuum the pump is pulling (right now it's after the valve, so doesn't read anything useful)
* Larger Vacuum Tank
* Install Additional/Larger Vacuum Tank to the system for more capacity
* More powerful Vacuum Pump
* More powerful Vacuum Pump
* Temperature Monitoring
* Temperature Monitoring
* Attach Control Panel to machine
* Mount Control Panel Box to machine ''DONE''
* Put on locking casters, or more permanent blocks/skid (machine is very heavy)
* make the platen stationary and the heater roll (complicated)
* Reduce the footprint of the machine (complicated)
== Authorizers ==
== Authorizers ==
=== How to Become an Authorizer ===
=== How to Become an Authorizer ===
Get an ok from the area host. Successfully run an authorization supervised by an authorizer.
Get an ok from the area host. Successfully run an authorization supervised by an authorizer.