Thermovacuum molding

Contact person
Name Dmitry N. Zykov
E-mail dmitrij.z52@mail.ru
Тел/факс 8 800 707 4999 ext. 118, +79101080182,+79026887871
Parts manufacture bythermovacuum molding The principal technology for parts manufacture in this production is vacuum molding followed by machining. Thermovacuum molding is a process of manufacturing 3D structures and products of irregular shape using thermoplastic materials. The key advantages of this method are high quality of products and a reasonable price even when producing even small batches, achieved through a low die making cost.
Materials employed forthermomoldingare polystyrene, ABS plastic, PC, ABS/PMMA, ABS+PC, ABS/TPU, LDPE and HDPE sheets.
JSC SAPT is now using this method to process up to 100 tons of sheets monthly.
The thermovacuum molding method consists in that a flat blank (sheet or film for thermomolding) is heated to a molding temperature and takes the form of the die due to vacuum created between plastic and die. This guarantees high quality and complete identity of products in a batch.
The company employs vacuum molding machines with upper, lower and twin heaters. The maximum dimensions of a sheet being molded are 1,500 x 2,700mm. of a material (sheet) being molded varies from 1.2 to 7mm. The maximum molding depth is 600mm.
Расположение координат в пространстве     The maximum operating space on the processing centers is as follows:
- along axis х – 1,600mm;
- along axis y – 3,600mm;
- along axis z – 850mm.
    The processing centers used in the manufacture of parts help:
1) machine parts and makemaster models in accordance with mathematical models.
2) minimize the machine operator’s interference in the parts manufacturing process. Basically, the operator’s main concern is preparatory and final operations, such as part setting and removal, too adjustment etc.
3) provide production flexibility:in order to machine different parts, the operator should only change the software, while already proven software can be used at any time and as often as needed
4) manufacture parts with high accuracy and processing repetition rate. Using the same software to producethousands of almost identical parts with desired quality. Processing parts with a complex spatial shape, which are impossible to manufacture on standard equipment.
The plant is equipped with ultrasonic welding units. Applying the ultrasonic welding technology substantially extends the parts manufacturing capacity, making it possible to produce assembled non-detachable plastic articles.
Механическая обработка изделий на станках с ЧПУVacuum molding dies are made at SAPT’s experimental area according to drawings, mathematical or prototype models. Depending on the requirements for molded product surface quality, ordered quantity, manufacturing accuracy andpricing policies, a die can be made from fiberglass, MDF, plywood, and duralumin. Master models are made on processing centers.
The apparent advantages of the vacuum-molding method are as follows: low cost of tooling, possibility of giving plastics a wide diversity of 3D and multilevel forms, possibility of processing multilayer andexpanded materials and materials with pre-applied print.
At present, SAPT manufactures a vast range of products from sheet plastics using the vacuum molding method: vehicle interior/exterior parts, railroad parts, medical goods, light engineering parts, promotional items, consumer goods etc
Термовакуумное формование Детали полученные методом термовакуумного формования Детали полученные методом термовакуумного формования Детали полученные методом термовакуумного формования


Plastics machining
Machining on 5-axis processing centers is used to produce dies, master models (in accordance with mathematical models) and products obtained by vacuum molding.
The maximum operating space on the processing centers is as follows:
- along axis х – 1,600mm;
- along axis y – 3,600mm;
- along axis z – 850mm.
The processing centers used in the manufacture of parts help:
1)machine parts and makemaster models in accordance with mathematical models.
2) minimize the machine operator’s interference in the parts manufacturing process. Basically, the operator’s main concern is preparatory and final operations, such as part setting and removal, too adjustment etc.
3) provide production flexibility: in order to machine different parts, the operator should only change the software, while already proven software can be used at any time and as often as needed.
4) manufacture parts with high accuracy and processing repetition rate. Using the same software to producethousands of almost identical parts with desired quality. Processing parts with a complex spatial shape, which are impossible to manufacture on standard equipment.
In die making, wide use is made of processing centers permitting master models to be produced in accordance with mathematical models.
Механическая обработка изделий на станках с ЧПУ Механическая обработка изделий на станках с ЧПУ Механическая обработка изделий на станках с ЧПУ Механическая обработка изделий на станках с ЧПУ

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