1. Sheet Fabrication Plet 370 Matt Eury Brian Martonik Mike McElhaney

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

3. Outline Materials Processes Equipment Secondary operations Applications

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

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

6. Disadvantages Cracking Bubbles Crazing Low Tolerances (Cell Casting)

7. Materials Acrylic Polycarbonate Polypropylene Polyethylene Nylon Acetyl

8. Processes to Form sheets Cell Cast Continuous cast Extrusion

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

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

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

12. Continuous Casting Sizes - varies Thickness - 1.5 mm

13. Extrusion Resin pellets melted by extruder Shaped by die

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

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

16. Equipment –Grinders –Dryers –Feedstock

17. Secondary Operations Cutting Decorating Drilling Forming Jointing Finishing

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

19. Secondary Operations Decorating –Printing –Painting –Stamping –Decals

20. Secondary Operations Drilling –Tapping –Hole saw –Drill bits

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

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

23. Secondary Operations Finishing –Sanding –Filing –Ashing –Polishing

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

25. Desired Properties of sheets –Toughness –Moisture content

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

27. Applications continued

28. Conclusion Great glass replacement Many applications Mass production easily accomplished