Common problems encountered in the cut sheet thermoforming process include thin spots, webbing, crowning and plug/pusher mark off. Syntactic foam can be used in various ways with both positive and negative tooling to alleviate these issues. Syntactic plugs result in improved material distribution leading to opportunities for down-gauging. Compared to other common plug/pusher materials such as wood and felt-covered wood, syntactic foam results in minimal plug mark-off and improved plug durability. Attached article as published in The Thermoforming Quarterly provides details.
Along with many other variables affecting thermoforming output, the selection of plug assist material is critical. While syntactic foam is widely recognized as an ideal plug material, the choice of which specific grade to use is often left to “whatever we used last time.” Base level epoxy syntactic foams provide a great starting point into the technology and are widely used for a variety of applications. Looking beyond the basics, though, frequently offers significant performance improvements and cost savings. The attached case study provides detail about how one manufacturer gained a 10% increase in average thickness at a critical location (also highlighted as a whopping 41% increase in minimum thickness at the same point) when working with HYTAC-B1X, a thermoplastic syntactic foam, that offered greater friction due to its performance enhancing makeup. The attached article offers details.
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