Instructions / Assembly

6 | P a g e
Usage and Fabrication Guidelines
THERMOFORMING Foam is a thermoplastic. It becomes soft when exposed to
intensive heat. This characteristic gives the material thermoforming
capabilities. 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 optimum
heating 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 sophisticated
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 times the sheet gauge.
(see illustration 4)
 Heating time 30 to 50 seconds per millimeter of thickness.
 Leave at least 20 times 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 after bending.
Pressure and Both of these methods require the use of air circulating 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 production
projects require more elaborate details than hot wire bending.
Basic Premises:
 Molds should not have sharp angles. (see illustration 5)
 Molds should have at least 5 degrees draft angles.
 Temperature should not exceed 750 degrees F for top heating
and 650 degrees F for bottom heating.
 Heating time 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.