T-Form

Throughput-Time Reduction and First Time Right Production for the Thermoform Industry by Introducing a Predictive Mould Design and Manufacturing System

The product design, mould design and production within the thermoforming process are currently based on craftsmanship and an iterative trial-and-error approach.

The T-ForM project aimed to develop a technology that is able to supply the thermoforming industry with:

• Design guidelines for thermoformed parts
• A complete proposal for an ideal thermoforming mould design based on a dedicated production simulation software tool by developing a predictive thermoforming mould design software tool
• Optimal thermoforming parameter settings coming from the developed predictive mould design software tool

The strategic objectives of T-ForM were:

• Objective 1: Shorten the time from part design to actual manufacturing by introducing design guidelines for thermoformed parts.
• Objective 2: Produce an easy-to-use, predictive mould design system for thermoforming based on, and connected to, a simulation system.
• Objective 3: Create optimal thermoforming parameter settings based on the optimised product and mould design and mould manufacturing.

The purpose of these objectives was to enable right-fi rst-time production and a throughput time reduction of 40%, as the trial-and-error approach becomes obsolete. Due to these reductions it is expected that costs will be reduced by 35%.

Organisational Information

Budget: €4.6M
Funding: €2.9M
Start Date: September 2005
Finish Date: November 2008
Duration (in months): 39
Lead Partner (Co-ordinator): TNO, Netherlands

Participants

Partners SME

	ProfitLogistics GmbH

Partners RTD

Results – What happened next?

A new mathematic model has been developed that describes the infl uence of friction and heat transfer during the thermoforming process. This model was implemented into existing production simulation software. The adapted production simulation software was then tested by performing validation simulations. A methodology to integrate more materials into the production simulation software in the future was also developed.

Based on a fully-instrumented laboratory thermoforming machine, a new test method has been developed to determine optimised process settings for sheet materials. Furthermore, a methodology to integrate more materials into the T-Form software has been developed. After the developments of detailed designs of algorithms for both thermoforming settings and predictive mould design, activities have focused on the software development of the T-ForM predictive mould design module. Several versions of this software have been distri buted amongst core SMEs and, after their recommendations, further distribution at a national level is under way.

The development was divided in two parallel items: first, the basic software structure and independent units; and second, the algorithms with processing know-how. The prototype software tool was validated by four real-life case studies.

In order to collect the necessary information about the six validation cases, data gathering from the partners was performed. Process parameters, part, mould and machine characteristics about the validation cases have been collected via a questionnaire. For currently available costing tools, a patent search and web search were performed. Considerable effort was invested in setting up a fair comparison document and timetable for the validation cases. This was to avoid any deviations in the validation period and ensure accuracy.

The future exploitation strategy has been devised. All IAGs have effectively recruited thermoforming-related companies as national SMEs for the project. This was partially supported by a huge number of press releases and two scientifi c publications. The training matrix is under development: draft and detailed specifi cations have been prepared and a start has been made on the fi nal modules on topics that are not dependent on the ongoingresearch and validation. Questionnaires were prepared and completed by nominated trainers to determine their expertise so that the ‘Train the Trainer’ module can be compiled accordingly.

The most remarkable results so far together with expected end results are:

• New heat transfer and friction model with an user-friendly graphics interface in existing simulation software
• Validation of upgraded simulation software
• Identification of necessary experiments to generate material data to integrate more materials into T-FORM and T-SIM
• New test method to determine optimised process settings for thermoforming
• Optimised process settings for materials chosen by the core-SMEs determined by the use of the new test method
• First version of software T-ForM module ready
• Validation by the national SMEs of the prototype software tool
• First approved set-up of validation geometries
• The continuous developments and frequent dissemination towards National SMEs is resulting in greater awareness and enthusiasm of what the impact of T-ForM will be for SMEs

Project website: www.t-form.eu