Sheet Fabrication Plet 370 Matt Eury Brian Martonik Mike McElhaney

Objective To understand sheet fabrication Learn it’s processability Learn the applications

Outline Materials Processes Equipment Secondary operations Applications

Introduction Several Sheet fabrication processes Many materials used Wide range of applications

Advantages Light weight Weather Resistance Colors Good optical qualities High impact resistance Cost (glass)

Disadvantages Cracking Bubbles Crazing Low Tolerances (Cell Casting)

Materials Acrylic Polycarbonate Polypropylene Polyethylene Nylon Acetyl

Processes to Form sheets Cell Cast Continuous cast Extrusion

Cell Casting Poured between sheets of glass PVC gasket Heat process causes reaction –Good surface quality and optics –Low optical distortion

Cell Casting Sizes –2 m by 3 m Thickness –2 to 12 mm

Continuous Casting Poured between polished steel belts –Belts heat and cool material –Highest productivity –High molecular weight –Harder surfaces –Isotropic shrinkages

Continuous Casting Sizes - varies Thickness mm

Extrusion Resin pellets melted by extruder Shaped by die

Extrusion Sizes –Up to 4 meters Thickness –.25 to 15 mm

Equipment Auxiliary Equipment –Blenders –Screen changers –Melt Pump –Static Mixers –Texture Rolls

Equipment –Grinders –Dryers –Feedstock

Secondary Operations Cutting Decorating Drilling Forming Jointing Finishing

Secondary Operations Cutting –Band Saws –Circular Saws –Knife –Laser Cutting –Water Jet

Secondary Operations Decorating –Printing –Painting –Stamping –Decals

Secondary Operations Drilling –Tapping –Hole saw –Drill bits

Secondary Operations Forming –Thermoforming –Presses –Clamps –Cold forming

Secondary Operations Jointing –Cementing –Adhesives –Dip and soak –Ultrasonic welding

Secondary Operations Finishing –Sanding –Filing –Ashing –Polishing

Desired Properties of sheets Sheet properties –Dimensions –Surface type –Orientation –Contamination

Desired Properties of sheets –Toughness –Moisture content

Applications of Sheets Signs Picture frames Instrument panels Safety shields Hot Tubs Glass Replacement

Applications continued

Conclusion Great glass replacement Many applications Mass production easily accomplished