I have not used this process in any other week because well, no other process includes heat and vacuum at the same time, with the Target of making a case for something.
This week was a little too messy because of the machine. I decided to do a thermoforming process.
This is basically making a moldable material like PET take the outer shape of anything. This process needs 4 main components
The machine will heat the material until it is deforming without breaking, while this is happening you have to place the mold and get the machine ready for the vacuum.
That's the quick explanation, but this has more steps. The design of the has to have some specifications and you have to know how to use the machine.
Let's start with showing a quick video of how does this work.
There are many error on that video but let me explain the creation of the mold. There are 5 main things you have to keep in mind while doing the mold
Go back again to the list to read what does each one mean.
Alright, so those are the 5 basic things to keep in mind while doing the mold, There are a few more, but I'm not making something very precise. So we can keep with this.
Making it was easier than I thought it would be. I went for using MDF and 3D printed parts and as my original part already had no 90º walls I just had to divide it in its faces. As the original design already had angles on its walls I I just had to consider the extra 1%.
This is the top part of the mold for the case, there is the size plus a 1%. And the space for the lateral panels to fit are on the inside of the material, so the thickness of the material doesn't cause any trouble on the measures.
For the side panels there were two kinds, the panel that had the space for the wheels and the front and back panel, they are basically the same, starting with the following base. This was a little tricky because I had to consider the angle of the walls on a planar design. At first I thought I had to consider the angle on the edges, but I just had to define the distances and center everything creating the spaces for the MDF to stay together and that was it.
By defining the upper distance and the down distance there was no need to use angles and it had to fit perfectly on the design of the case. And same as the upper panel, the space for the material to fit is on the inside so the material thickness doesn't cause any trouble.
Let's go fo the side with the wheels, it is basically the same as the last part but with a semi circle on it for the wheels.
So the assembly ended up something like this:
As I see it, seems pretty good, however there is something to notice
The edges doesn't fit as in a planar design, because this has angles, but this actually doesn't matter because the edges will be sanded and those gaps are not important for the process.
Then the mold for the wheels
And that's it. check out the to see wou to use the laser cutter for this process and the important things on it's design. And Check the printing week for more information about 3D printing
That's the only picture I had before sanding the mold, and as you can see, I had to sand the edges so the mold doesn't had any sharp edges. Once sanded It looked something lithe this:
The last step was adding the wheels mold.
Now it is ready for the thermoforming.
This was the messy part because it took me some attempts and a lot of material. by the way, before starting the process, here are some considerations to take into account. There are materials that can be used on this process and material that not. Here is a list of ome material that you can use and their thermoforming temperatures.
The first column left right are the names of the material that you can use, and the third column right left are the temperatures of the material to be thermoformed.
There are some material can not be used on this process so just keep among the shown on the image.
I decided to use transparent polycarbonate because it is very similar to the one used on toys cases.
This process was quite easy once understood. Basically the steps to follow are:
NOTE, it is recommendable to set the temperature a little higher than on the image, because there is a gap between the heater and the material so we have to compensate that.
NOTE, when pulling the heater, grab it with gloves, because as long as you use it the hotter it becomes, and it can burn you.