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VACUUM FORMINGPROCESS FOR

KYDEX PARTS

Prepared By

A.S.DESHMUKH

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KYDEXPROPERTIES

Formability :Excellent forming properties, easy machining andfabricating using conventional methods, furtherexpanding finished part possibilities.

For deep or hard to form parts or where good finisheddetail is required. KYDEX is unsurpassed.

Rigidity:KYDEX is more rigid than most other thermoplasticsresulting in parts that will deform less when loaded.

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KYDEX PART TO BE MANUFACTURE

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Kydex Sheet Wooden Frame

Need to clamp Kydex sheet between wooden frame withthe help of clamps as shown in snap.

Clamp

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Heaters are generally infra-red elements mounted within an aluminum reflector plate.In order to obtain the best vacuum forming results, it is essential that the sheet isheated uniformly over its entire surface area and throughout its thickness and reachthe Forming Temp or ( Plastic State). In order to achieve this it is necessary to have aseries of zones which are controlled by energy regulators.

Heating Temp.- Between 400 to 430F

Heating Time- 4 min

Heating of Kydex Sheet

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Vent Holes for evacuating air to creating Vacuum

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Forming Tool with Vacuum attachment

Forming Tool

VacuumChamber

VacuumAttachment:

Which suck airfrom vacuumchamber through

PVC connectingpipe

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Another Example

Forming Tool Kydex Part

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Forming Tool Kydex Part

Another Example

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Another Example

Forming Tool Forming Tool

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Setup while Vacuum forming For Ex.-

Kydex Heated sheet

Clamp

FormingTool

Vacuum

Chamber

Air Evacuatedto suckingKydex ontoForming Tool

Air betweenKydexsheet andTool

surface

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After Vacuum Forming

For Ex.-

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Hear we can see the part surface is not smooth, Excess material is formed on part surface, which iscalled Webbing.

As in this part that portion will be cut in final trimming no need to bother about that.

But if we want to avoid Webbing then female part of forming tool is required and need to match withmale part while vacuum forming.

For Ex.-

Excess Material (Webbing)

Forming Tool (Male)

Forming Tool (Female)

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For Ex.

Forming Tool (Male)

Forming Tool (Female)

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COOLING Once formed the Kydex must be allowed to cool before being released. Ifreleased too soon then deformation of the moldings will result in areject part.

For speed up the cooling cycle air flow is required.

Air Gun

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Formed Part Before Trimming

For Ex.-

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Part After Rough Trimming

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Finish trimming is required as per Drawing with the help

of jig & Fixture on Vertical or horizontal Saw M/c, CNC orHand Router.

Hand Router

For Ex.-

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