Design of Simple Multi-use Thermoforming Molds for the Beginner Machinist Designer
by
Shaka J.P. Thomhill
MASSACHUSETTS INSTITUTE
OF TECHNOLoGCY
Submitted to the
Department of Mechanical Engineering
in Partial Fulfillment of the Requirements for the Degree of
JUL 3 0 2014
LIBRARIESn
Bachelor of Science in Mechanical Engineering
at the
Massachusetts Institute of Technology
February 2014
C 2014 Massachusetts Institute of Technology. All rights reserved.
Signature redacted
Signature of Aut hor:
Certified by:
i-
V
Department of Mechanical Engineering
2014
February 3~
Februarv,321
Signature redacted
Steven B. Leeb
Professor, Electrical Engineering and Mechanical Engineering
Thesis Supervisor
Signature redacted
Accepted by:
Anette Hosoi
Professor of Mechanical Engineering
Undergraduate Officer
Design of Simple Multi-use Thermoforming Molds for the Beginner Machinist Designer
by
Shaka J.P. Thornhill
Submitted to the Department of Mechanical Engineering
on February 3, 2013 in Partial Fulfillment of the
Requirements for the Degree of
Bachelor of Science in Mechanical Engineering
ABSTRACT
The aim of a class with Engineering Design points at MIT is to help the students learn how to put
into practice different lessons and techniques in engineering a product. Beginner machinist are
sometimes held back by the time consuming process of constructing proper housing in electronic
dominant disciplines. The aim for this thesis was to devise a simple multi-use molding system to
facilitate learning for the beginner machinist.
Five schemes were used in conjunction with seven shapes and sixteen different detail designs to
come up with thirty seven molds, out of the five hundred and sixty mold possibilities, which
students may use in multiple ways. Choosing Renshape*5025, a polyurethane based thermoset
foam for the mold material, allows the limited facility in the EDS lab to repair and manufacture a
variety of mold designs. With the addition of plywood base board for added weight and grip
ensures that the forms are easily removed without damaging the molds.
Thesis Supervisor: Steven B. Leeb
Tile: Professor, Electrical Engineering and Mechanical Engineering
3
Table of Contents
ABSTRACT
Acknowledgments
Table of Contents
List of Figures
List of Tables
1. Introduction
2. Thermoforming Basics
2.1. Mold Creation
2.1.1. Mold Design
2.1.2. Mold Criteria
2.2. Material Clamping
2.3. Material Heating
2.4. Material Pre-stretch
2.5. Vacuum and Mold Plug
2.6. Form Cooling and Release
2.7. Form Trimming and Finishing
3D printing Comparison
3.1. Cost
3.2. Utilization
4. Method of Mold Design
4.1. Shape Factors
4.2. Detail Selection
4.3. Design Tools
4.3.1. Solidworks
4.3.2. Mastercam X6
4.3.3. Router (Techno or Shark pro)
4.3.4. Hand and Belt Sanders
4.3.5. Table Saw
4.4. Material Selection
4.5. Quality Control
3.
5. Mold Design
6. Conclusion
7. References
3
4
5
7
8
9
9
10
10
10
11
11
12
12
12
13
13
13
13
15
15
17
17
17
19
20
20
21
21
22
22
24
25
5
8. Appendix
A. Model Drawings
B. Base Drawings
C. Sample G-Code
26
26
69
81
6
List of Figures
Figure 1: a) Male mold with suggested draft angles b) Female mold with suggest draft angles 2 10
Figure 2: a) Male mold with relief holes and base plate b) Female mold with relief holes and base
plate............................................................................. 11
Figure 3: a) Shape Comparison with red representing space with high probability of not being
used...... ....................................................................................................................................
16
Figure 4: a) rectangle shape with EECS logo b) MIT logo with same base dimension as part a
Both use the same baseplate and need the same mated part.....................................................
18
Figure 5: Sample constructed tool path done in Mastercam X6. Left are the tools chosen with
their respective path type. The right shows the predicted movement of the tools.................... 19
Figure 6: Simulated outcome of constructed tool path to visually check for mistakes in tool
movem ent......................................................................................................................................
19
Figure 7: Dimensional Schematic of Custom Circuit Board made for EDS lab (EDS-board)..... 23
7
List of Tables
Table 1: A utilization breakdown of ideal project cycle with weekday 9-5 access to lab........ 14
Table 2: Sample projects with some significant criteria found. Total is for all projects classified
15
from issues 1-345...........................................................................................................................
8
1. Introduction
MIT students learn through many classes the theoretical approach to building mathematical
models of their ideas. Courses like Microcomputer Project Laboratory, 6.115, and Power
Electronics Laboratory, 6.13 1, offer hands on approach to teaching the students how to manifest
their ideas. In the Electrical Engineering and Computer Science discipline, an introduction to the
machines and tools used to build physical prototypes and manufacture goods are not an early
focus in the curriculum. If the students have a lab equipped with ready to use molds to make
casing for alarm clock or mp3 player dock that they designed then this will be beneficial. This
will allow the students to focus more on the Electrical and Computer Science component and
less on the machining. Furthermore with a class as large as 80 students, thermoforming molds
would be cheaper and faster than most other forming methods. Appendix A shows 43 mold
designs that when used together allows the student to do just that. Making it easy to create a case
for the iPod or cover for a speaker.
2.
Thermoforming Basics
There are many ways to manufacture goods but since the invention of motorized vacuum pumps
in the 20 Century, engineers started playing with thermoforming. Although new techniques and
materials have been found over the years, the basic process is still the same.
9
2.1.
Mold Creation
2.1.1. Mold Design
First the decision for a male or female mold is decided. Both mold options are shown in figure 1.
This is usually determined mainly by end shape. Both molds forms leave the top portion with a
thicker layer of plastic2 . Depending on which side of the form requires more strength can
influence the choice of male or female.
I
a)
b)
Figure 1: a) Male mold with suggested draft angles b) Female mold with suggest draft angJes z
2.1.2. Mold Criteria
F or a form to be made properly three things need to be in place. First is the draft angle, which is
a slight angle of vertical surfaces to help the form release from the mold. This is because most
materials used in thermoforming shrink. Because most molds are meant to be reusable draft
angles make it possible to separate mold from finished form without damaging either. Second is
a Base plate. This ensures that the plastic does not total encase the mold on the 6th surface and
allows the mold to be released from the form. Base plates can also add weight to the mold to
10
allow for easier release. Last is the relief hole. Air can be trapped in pockets between the mold
and the form. These holes allow the removal of air pockets to let the form fully conform to the
mold. 2
Male
Female
a)
Relief
Holes
Holes
Figure 2: a) Male mold with relief holes and base plate b) Female mold with relief holes and base plate
"
.".~
2.2.
Material Clamping
After the mold has been constructed, a sheet of forming material is secured in place. This
clamping also creates a seal for the vacuum to function. The frame of the clamp needs to be
strong enough to ensure the sheet is held firmly while resisting the vacuum pressure. Additional
it must ensure that it can be adjusted to the different thickness and dimension of the sheet.
2.3.
Material Heating
A heat source it place over plastic to the point of phase change from solid to liquid. In order to
get best results heating should be done uniformly over the entire sheet and through its thickness.
Most vacuum formers have variable zones that can be customized to best match the dimension
and thickness of the sheet material. Overheating the sheet material can cause webbing and other
11
deformities. Under heating can cause decrease definition of the mold. Heat time is complex to
predict and so some trial and error is need to find the appropriate heat time
2.4.
Material Pre-stretch
When the plastic is ready for forming, it can be pre-stretched to ensure a more even wall
thickness when the vacuum is applied to the mold. Pre-stretch can be useful when drawing parts
with more depth. This is usually performed by a release of compressed air under the sheet.
2.5.
Vacuum and Mold Plug
Once the material is pre-stretch, the vacuum can be applied to sheet to form over the mold. Some
machines us two stage vacuums to ensure the rapid molding of the heated material. Mold Plugs
are optional and can then be used to help further form the sheet to the desired shape. Plugs are
usually used when forming multiple impression male molds as they can be situate near each
other without the worry of webbing.
2.6.
Form Cooling and Release
Once the sheet is formed, it must be allowed to cool before being release from the clamp and the
mold. This can be helped by forced cooling with a powered device spraying mist on the mold or
by applying a damp cloth. If the sheet is released too soon it will warp and deviate from the
intended shape
12
2.7.
Form Trimming and Finishing
Now that the sheet is formed, cooled and removed from the machine, excess plastic can be
trimmed. Holes, slots and cut-outs can then be performed to get it to the desired final shape.
3.
3D printing Comparison
Additive Manufacturing methods are very capable to make a variety of complex and simple
shapes or objects. It also is not limited in the forms that can be made when compared to
Thermoforming. The EDS lab only looked at one other option beside Thermoforming and that
was 3D printing.
3.1.
Cost
The price of 3D printing material is anywhere from $20-$180 per kg dependent on the color and
type of plastic'. Comparing this to the price of Sheets of plastic for thermoforming, which range
.
about $1-$10 per kg, we can see one of the drawbacks of the materials of 3D printing 4
Additionally the cost of industrial thermoforming can range from $5,000-$20,0002. 3D printers
have dropped in price to about a few hundred dollars but these have a very limited foot print. In
order to ensure breath of scope for size a larger more expensive model would have to be used
and with prices ranging upwards of about $10,000+1.
3.2.
Utilization
The second factor we compared was utilization. Table 1 gives a breakdown of the utilization that
we can expect in a conservative class with 80 students, lab only open from 9-5pm on weekdays
and only one project to do the whole semester.
13
Table 1: A utilization breakdown of ideal project cycle with weekday 9-5 access to lab.
Utilization Table
# of Students
80
length of Project
3
Lab availability for
52
Method
~~ ·~~1~'1-i.~:~~
c
-
Utilization w/1 machine
Low
High
Low
High
Avg.
3.0
26%
154%
90%
24.0
410%
1231%
821%
, 8.0
J
'.
Hours I Month
Job completion range
r~}@ffi{~itffi~wi~--'l 0.5
L~-.~~~~-~J
Months
Optimal
Stations
I
~_ _ _ _ _ • _ _ _ > ___________
-
_l
As can be seen from the table you would need nine 3D printers to get close to the same
utilization of one vacuum former. This information further supports our chosen forming method.
14
4. Method of Mold Design
4.1.
Shape Factors
The first determination of mold design is the shape of the mold. Research was done mostly by
analyzing project suggestions in Maker Magazine. Table 2 is a breakdown of sample data taken
from the magazine.
Table 2: Sample projects with some significant criteria found. Total is for all projects classified from issues 1-34 5
Name
Page
Volume
-
Desktop Rail Gun
12
Principles
-
Co plete
Casing
EE Focus
Both
_
1
Physics
0
0
0
34
1
EE
0
1
0
49
3
EE
0
1
0
50
1
MechE
0
0
0
0
86
3
Lego Soccer
88
6
EE
Robotics
0
0
1
0
0
Mousey the Junkbot
96
2
Robotics
1
0
0
Gun-Controlled Alarm Clock
100
8
EE
0
1
0
Magnetic Stripe Reader
106
1
EE
1
1
1
Electronic Test Equipment
158
10
How to
0
0
0
Microcontroller Programming
158
4
How To
0
0
0
Midi Control
158
7
EE
1
1
1
Moldmaking
160
8
MechE
0
0
0
38.30%
31.91%
19.15%
Glowstick A Go-Go
MOD your ROD
Kite Aerial Photography
Halloween
Haunted House
Controller
All Issues Total
Complete Casing is set as "1" if the project was completely cased. EE focus is set as "1" if the
project's main principle discipline was Electric Engineer. As can be seen by the results only
about 38.30% were completely enclosed. Of the total "Complete Casing" close 50% of them
were EE focus. This leads to evidence that the Shape of the casing can almost be entirely
determined by the electric circuit board on the inside. This let us know that we can have the best
success of having a set of mold be useful for a variety of situations if they can meet a few
15
criteria. One is that the case totally encloses the standard circuit boards use by the lab. Extra
space can be added in case of wiring, capacitors and other components. Next criteria is that since
most circuit boards are four sided then rectangle/squares will be the dominate shape needed.
Another criterion that becomes obvious is that more shapes will be needed to cover additional
creativity. But these less dominate shapes can't deviate too much on the # of sides as when we
deviate from four sides we end up with more wasted space. This is visually shown in fig. 3
giving reason not to deviate more than ±2 sides beyond 4.
Shape Comparison
Figure 3: a) Shape Comparison with red representing space with high probability of not being used.
16
4.2.
Detail Selection
After the shape choices become apparent, a small amount of detail can be added to some shapes
to help the beginners along. In selecting details to be used, three criteria were used. First, the
detail could not be too complex in detail because complexity increased the size of mold as
thermoforming cannot handle too much small detail. Secondly, the detail can't take up too much
of the top surface as this might restrict creativity and multi-purpose affinity of the mold. By
looking again at Figure 3 we can estimate that at most 50% of the total surface can be used. So
we can designate our neutral or empty space to be 50-100% of the shape surface. Lastly, the
details need to belong to themes that will be favorable to MIT students. Acceptable themes could
be School Spirit, Generation Tech friendly or part of the Nerdist culture.
4.3.
Design Tools
The process used to create mold varied by the shape and detail chosen. The order of design tools
used is fairly consistent even with the variations.
4.3.1. Solidworks
Initial CAD models of chosen shapes and details are made to the correct perspective. All similar
shapes are kept to the same base dimension for ease of building a mated part for it. After the
CAD is finalized a drawing is made of model.
17
Figure 4: a) rectangle shape with EECS logo b) MIT logo with same base dimension as part a. Both use the same
baseplate and need the same mated part.
18
4.3.2. Mastercam X6
The drawing file is then imported into Mastercam X6. Here tool paths are constructed in Figure
5. The tool paths are then check visually with a computer simulation as can be seen in Figure 6.
Figure 5: Sample constructed tool path done in Mastercam X6. Left are the tools chosen with their respective path type.
The right shows the predicted movement of the tools.
Figure 6: Simulated outcome of constructed tool path to visually check for mistakes in tool movement.
Once the tool path is verified the G-code is generated to use with a CNC machine.
19
4.3.3. Router (Techno or Shark pro)
The G-code is loaded in to a router to do the rough cut of the mold shapes. Most detailing is done
here also to ensure the detail is placed correctly on the mold. Several router bits are used in this
stage. The material is first faced with a 2.5 facing bit. Initial cuts and outlines of the detail is
done with the 1/8" and %A"straight bits. The chamfers and finer detailing is done with the V-60*
and V-90* bits. Finally the rough mold is cut out of the material with the longer fluted '2"
straight or 3/8" spherical bits. The base plates are also cut out at this point
4.3.3.1.
Router Bit List
a) 2.5" Face bit %" shank w/2 3/4" flutes
b) 1/8" Straight bit 1/4" shank w/2 %" flutes
c)
1/4" Straight bit
/"
shank w/2 %"flutes
d) 1/2" Straight bit A" shank w/2 1.5" flutes
e) 3/8" Spherical bit %" shank w/1 2" flute
f)
1" V-60* %" shank w/2 1" flutes
g) 1/2" V-90 0 %" shank w/2 1" flutes
4.3.4. Hand and Belt Sanders
The rough molds are not sanded to remove any flash or burs. Non-straight edges are finish here
by using the sander at a 70 angle to apply an initial draft. This is follow by hand sanding with
20
papers and files to smooth out the drafts and remove any burs in the detail. At this stage the base
plates are also sanded my the hand and belt sanders to remove any burs from the material
4.3.5. Table Saw
The last design tool is a table saw. A flat edge jig is made to facilitate cutting a 7* draft angle on
straight edges. This jig allows a consistent draft to be made with minimal effort and maximum
safety.
4.4.
Material Selection
Choice of material of Mold had a few top choices. Aluminum was foremost of options for the
mold but due to the restrictive availability of machining tools in the EDS lab it was not used.
One goal was to have the molds easily repaired and/or remade from scratch. To use Aluminum
as a material the lab would need a CNC milling machine at a minimum. The only CNC machine
in the lab was a router. With this in mind a polyurethane-based thermoset foam board was used
called Renshape® 5025. The price of Renshape per kg is slightly higher but, with its
machinability being better that wood, made this the perfect choice. The base plates were also not
made out of Aluminum for the same reason as the mold. Weight was durability were the main
factors in this part so wood was chosen. Ply would seem to best fit the need so a no gap Lauan
plywood was used to keep the structural integrity of the base in a vacuum.6
21
4.5.
Quality Control
Quality control was performed once the machining process was complete. Step 1 involved the
use of a Caliper to verify the critical dimensions. The critical dimension depends on the stock
shape of the mold. This ensures that all similar shapes would be of the same dimension and could
therefore reduce the number of configurations of bases that needs to be prepared for the form.
Step 2 of quality control was to use an Angle Block to verify the 70 Draft for easy release. If
either step failed by more than 5% accuracy the mold would be sanded by hand till verification
was met.
5. Mold Design
The molds that will be used in the EDS lab had to have the capacity to fit a circuit board made
for the project classes that are being held there. Figure #### shows a solid work sketch of the
dimensions of the EDS lab Custom circuit board or EDS-board.
22
7.44
Figure 7: Dimensional Schematic of Custom Circuit Board made for EDS lab (EDS-board).
With this as the main criteria for restrictive dimensions, 5 Circuit schemes were formulated and
are reflected in the naming schemes of all drawings in Appendix A. OC is for any mold that the
EDS-board would not fit. This was chosen to accommodate small independently chosen boards
like some of the popular microprocessors (i.e. Arduino.) The IC scheme is designate for any
shape that can comfortably fit one EDS-board. 2CP is the designation for a mold that can hold
two EDS-boards arranged in parallel to each other. 2CS is the designation for a mold that can
hold two EDS-boards stacked one on top the other. Finally 4CSP is the scheme that can hold 4
EDS-boards in a 2x2 stacked formation. These 5 Schemes, combined with 7 choices shapes and
16 different Details are used to make over 30+ different molds.
23
6. Conclusion
The aim of a class with Engineering Design points is to help the student learn how to put in to
practice different lessons and techniques in engineering a product. Beginner machinist are
sometimes held back by the time consuming process of constructing proper housing for
electronic dominant disciplines. The aim for this thesis was to devise a simple multi-use molding
system to facilitate learning for the beginner machinist.
Five schemes were used in conjunction with seven shapes and sixteen different detail designs to
come up with thirty seven molds that students can use in many different ways. Choosing
Renshape* , a polyurethane based thermoset foam, for the mold allows the limited facility in the
EDS lab to repair and manufacture a variety of mold designs. With the addition of a plywood
base board for added weight and grip, allows the forms to be easily removed and reuse the
molds.
In the future if a CNC mill is ever added to the Lab, The molds can be easily remade and
maintained in Aluminum using the G-Code already generated. Wood can also be used to remake
molds but its machinability is not as good as that of the foam but its durability is better for a
longer lasting mold core.
24
7. References
1. 3ders.org - price compare 3D printing materials. (n.d.). Retrieved February 01, 2014, from
http://www.3ders.org/pricecompare/
2. Formech. A Vacuum Forming Guide.
3. Lienhard, J. H. (2010). Heat Transfer. Journal of Heat Transfer, 82(1), 198.
doi: 10.1115/1.3246887
4. Plastipedia: The Plastics Encyclopedia - Vacuum Forming. (n.d.). Retrieved January 31,
2014, from http://www.bpf.co.uk/plastipedia/processes/vacuum-forning.aspx
5. Maker Media. Maker Magazine, 1-34. Retrieved from www.makezine.com
6. Technology, H. A., & Center. Renshape Properties. Retrieved from
http://www.freemansupply.com/datasheets/renshapepolytoolingboards/5020.pdf
25
Appendix
Appendix A: Model Drawings
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Appendix C: Sample G-Code
(PROGRAM NAME - SAMPLEGCODE)
( 1/4 STRAIGHT BIT TOOL - 1 DIA. - .25)
N100TlM6
N110S18000M3
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