Vacuum forming of compound curved surfaces with a variable geometry mold

Most rapid prototyping technologies focus on small three-dimensional parts and are generally not applicable to fabrication of large, thin, curved surfaces. This initial study demonstrates a method for producing prototypes of compound pound curved surfaces with a variable configuration vacuum forming...

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Bibliographic Details
Published in:Journal of manufacturing systems 1998-01, Vol.17 (5), p.325-337
Main Authors: Kleespies, H.S., Crawford, R.H.
Format: Article
Language:English
Subjects:
Automation
Computer simulation
Cost control
Design
Geometry
Manufacturing
Metal forming
Molding
Process Modeling
Processes
Product development
Prototypes
Rapid Prototyping
Rubber
Studies
Vacuum Forming
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Summary:Most rapid prototyping technologies focus on small three-dimensional parts and are generally not applicable to fabrication of large, thin, curved surfaces. This initial study demonstrates a method for producing prototypes of compound pound curved surfaces with a variable configuration vacuum forming mold composed of a number of discrete pins and a rubber interpolation sheet. A multi-parameter design study, using theoretical, numerical, and experimental results, explored the feasibility of building prototype surface parts with a variable molding process. The analyses provide fundamental design relationships for a variable geometry thermoforming mold as a function of the surface quality and the minimum achievable radii of compound curvature. Prototype parts of ABS and styrene thermoplastics were vacuum formed with the variable geometry mold. It was demonstrated that a variable configuration mold can be automated so that shapes are assumed quickly and directly from computer surface models. Rapid prototyping of curved surfaces with a variable geometry vacuum forming mold is shown to be a feasible process, but with limitations of surface smoothness and achievable curvatures.
ISSN:0278-6125
1878-6642
DOI:10.1016/S0278-6125(98)80001-0