Thermoformed plastic products: separating scrap from the main part

In the thermoforming of plastic products, there are several reasons why the main part might not separate correctly from the scrap:

Inadequate cutting: If the cutting is not done precisely, the main part might remain attached to the scrap.
Inappropriate material: Some thermoplastic materials may have properties that make separation difficult, so choosing the right material for the specific process is crucial.
Mold design: It’s crucial to plan for part removal during the mold design phase to avoid any separation issues later on.
Temperature Control: Uneven or inadequate temperatures during the thermoforming process can cause deformations that make it difficult to separate the part from the scrap. It is essential to:

Maintain a uniform temperature across the entire surface of the plastic sheet-feed to avoid bubbles, weak spots, or deformations.
Heat gradually to avoid thermal shocks that could compromise the material’s integrity.
Use temperature sensors and automatic control systems to continuously monitor and adjust the temperature during the process.
Use a cooling system to prevent overheating and, after forming, consolidate the part into the desired shape.

Pressure and vacuum: Inadequate control of pressure and vacuum during the process can affect the quality of the forming and consequently the ease of separating the part.