Portable Vacuum Forming Machine

Abstract

forming machines are widely used in the advertising industry for making 3D signage, packaging industry for packing different components such as plastic casing for headphones etc. and orthotics parts in the medical field. The machine is available worldwide but is very expensive. We wanted to manufacture a customized version for our local market which can be serviced locally at minimum cost. The aim of this thesis was to develop a Vacuum Forming Machine that can form ABS, high impact plastic (HIPS) and acrylic material in a vacuum forming process. This is not a novel idea but a transfer of technology to Pakistan using reverse engineering. Since all the vacuum forming machines work on the same principle despite having very different designs the working principle can be achieved with several designs. So, in a nutshell our design is considerably different which will achieve the same objective. Currently, there is no company in Pakistan who can work on these moderately advanced technologies with the aim of indigenization and local production. The vacuum forming process involves a series of steps that are performed in a specific order. It starts by heating a plastic sheet, placing it onto a shaped vacuum forming tool and applying vacuum, allowing the plastic sheet to cool down and eventually trimming the required part [1]. The developed machine has high production with consistent superior quality that combines very accurate high vacuum system, smart sensors, manual adjustable gripping system, and heating system with a sliding guide, a moving mechanism for pattern, and a simple user interface. These small components were integrated to make a full functioning, stand-alone, cost-effective vacuum forming machine. The machine was designed with an objective that it should be easy to operate by a common unskilled operator. This machine can form 3D parts with complex contour curves with high accuracy and consistency. Such parts are impossible to make with manual method of heating and bending with hand. During the production of this machine, part and sub-assemblies were outsourced for production. It is important to point out that there was no need to build a new plant or assembly line for the manufacturing of this machine as it was made at various mechanical fabrication shops that had good fabrication facilities. The critical part of this development laid in system integration. We designed and developed a customized solution in the form of a vacuum forming machine that is not only beneficial for our local industry but also has potential for export to other countries. This selection was based on extensive interaction in which we realized that there was a strong need for this in our local market. Moreover, this project strengthened the industry-university linkages and developed a trend of cooperation. This cooperation is the need of the day. There are very few companies in Pakistan which have this technology but most of the small players do not have access to this. This locally developed machine can be repaired in Pakistan with ease and will be tailored and sized for our local market needs. The use of this machine will create jobs and improve the manufacturing quality of formed parts.