Instructions / Assembly
Table Of Contents
6 | P a g e
Usage and Fabricaon Guidelines
THERMOFORMING Foam is a thermoplasc. It becomes so when exposed to intensive heat. This
characterisc gives the material thermoforming capabilies. However, since it is
expanded PVC foam, it is important to know that it lacks the draw depth of solid PVC
sheets. Heat bending, pressure and vacuum forming are among the methods that may
be used to thermoform Foam. Depending on the method used, the opmum heang
temperature of the sheet should range between 250 degrees F and 350 degrees F
Heat Bending Heat bending is a common process that does not require sophiscated equipment. Most
bending can be accomplished with strip or radiant heaters, hot air ovens, and, for thin
panels, hot air welding guns.
Basic Premises:
Minimum radius of bend should be 3 mes the sheet gauge. (see illustraon 4)
Heang me 30 to 50 seconds per millimeter of thickness.
Leave at least 20 mes sheet gauge for border when hot line bending angles.
Heat both sides when bending sheets 5mm to 10mm.
Always make sure material is cooled before using aer bending.
Pressure and Both of these methods require the use of air circulang ovens capable
Vacuum Forming of reaching temperatures between 260 degrees F and 280 degrees F or radiant heat
panels capable of reaching temperatures exceeding 700 degrees F. The usage of molds
is required for the thermoforming process. These methods are ideal for consistent, high
producon projects require more elaborate details than hot wire bending.
Basic Premises:
Molds should not have sharp angles. (see illustraon 5)
Molds should have at least 5° dra angles.
Temperature should not ex ceed 750° F for top heang and 650 degrees F for
boom heang.
Heang me should be between 15 and 20 seconds per millimeter of thickness
Sheets must be securely clamped to molds to minimize shrinkage
Sheets must be completely cooled before removing from mold.
Illustraons 4 & 5
Minimum Angle:
Bend Radius
Angle = 3 x gauge
Vacuum Forming: PVC Sheet
Vacuum Line