In this process, a TAFNEX™ Sheet or tailored blank is heated above its melting point and then formed into the desired 3D shape using a Thermoforming press. Depending on the required surface quality, low-cost molds or even one-sided molds can be utilized, making Thermoforming a highly cost-efficient process, even for low production volumes. However, Thermoforming has limitations in terms of complexity and typically requires post-processing.
Thermoforming stands out with its significantly lower investment costs compared to other thermoplastic composite processing methods. This includes the costs for the mold, which can be minimized by using single-sided molds and a double diaphragm forming process, for instance. Consequently, Thermoforming is also well-suited for relatively low production volumes.
Thermoforming allows for short cycle times, typically ranging in the order of a few minutes, depending on the application.
A complete Thermoforming production line can be automated with robots and conveyor belts, managing operations from handling the sheet material to post-processing tasks.
The first step involves heating the TAFNEX™ Sheet or tailored blank above its melting point. This is typically achieved outside the mold using one of three heating technologies (listed below). However, some companies offer in-mold induction heating technology, which enables the entire Thermoforming process to occur within the mold.
1. Heating the sheet above its melting point
2. Positioning the sheet in the open mold
3. Closing the mold + forming
4. Consolidation / cooling
5. Opening the mold
6. Demolding
For heating the TAFNEX™ Sheet or tailored blank outside the mold one of these technologies is utilized. Usually, infrared (IR) heating is used due to its efficiency, especially for thinner components. For very thin sheets or blanks, one-sided IR heating can be employed to reduce investment and operating costs.
+ very short heating times
+ energy-efficient
- temperature gradient across sheet thickness
-> Used for all type of sheets
+ very homogeneous heating
- very slow heating times (however, short cycle times are achievable through a paternoster system)
-> Typically used for very thick sheets
+ short heating times
+ homogeneous heating
+ pre-consolidation through applied pressure
- low matrix concentrations on the surface & poor surface quality
-> Used when pre-consolidation is beneficial
A thin TAFNEX™ Sheet is thermoformed into a high-performance diving fin blade. The layer structure is optimized to achieve the ideal balance between stiffness and flexibility for an exceptional underwater experience.
Through Thermoforming, a TAFNEX™ Structural Sheet can be shaped into a high-performance, lightweight bicycle saddle, offering strength and design flexibility.
Thermoforming a TAFNEX™ Design Sheet creates a drone cover that not only adds style but also safeguards the drone's interior components.
The marble-like appearance of TAFNEX™ Design Sheets perfectly suits luxurious furniture, which is put into shape via Thermoforming.