First Thermoformed and Injection-Molded Pieces!

Last Thursday we made our first thermoform and injection molded pieces! Dave taught us how to use the machines and we now have our first couple of test pieces for the thermo-window and the snap ring. 

Thermoforming the Window:

Before using the thermoform machine, vacuum holes had to be made on the thermo-window die. 

Carefully making vacuum holes on the die.
Did I have to stand on a stool to reach? Maybe. . .  

Once the holes were made, Dave taught us how to use the thermoform machine, which was relatively easy to understand. A video showing the process is shown below. The scary part of the whole process is the really loud sound the clamp makes when it engages. 

  



Three different trials were run using the clear thermoform material. During each trial, I tried to increase definition of the piece made in order for it to flush well with the ring piece. 

The team watched the first couple of trials together.
One of the perks of being short and not being able to see
what the machine is doing is getting to use the step ladder. ;)

Injection Molding the Ring:

Daivon learning how to use the injection mold machine.

Elyud collects parameters for each trial run. 

  

An injection molded ring piece
(Note: color shown is not the color to be used.)

We ran a couple of trials for the injection molded piece, changing different parameters in order to get rid of the weld line and reduce dishing on the piece.

Conclusions:

At the end of our lab time, we were satisfied with our first couple of trials. We recorded the parameters used for each trial, taking note of what worked and what didn't. As you can see below, our first two pieces fit well with each other! I was initially worried I would have to re-machine the thermo-window die because I had forgotten to fillet each island, but it turns out it didn't really make a difference. Even though the thermo-window piece features were well defined at the end of the part making trial, it fit well with the ring. 

Fitting the injection molded ring to the thermo-window.

And now I present you all with our "Awkward Dance." It all started with Daivon while we waited for our turn to use the machines. . . We either did that, or like Amelia and Daivon are doing in the picture below, we looked out of the windows in the shop. . .

Till next time!