Thermoforming of Single and Multilayer Laminates

Thermoforming of Single and Multilayer Laminates

Plastic Films Technologies, Testing, and Applications

1st Edition - November 7, 2013

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  • Author: Syed Ali Ashter
  • eBook ISBN: 9781455731862

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Thermoforming of Single and Multilayer Laminates explains the fundamentals of lamination and plastics thermoforming technologies along with current and new developments. It focuses on properties and thermoforming mechanics of plastic films and in particular single and multilayered laminates, including barrier films. For environmental and economic reasons, laminates are becoming increasingly important as a replacement for solid sheets and paint finishes in many industries, including transportation, packaging, and construction. Yet the processes of film formability during the extensive deformation and elevated temperatures experienced in conventional processing technologies, such as thermoforming, are poorly understood by most engineers. This book covers production processes, such as extrusion, calendaring, and casting, as well as mechanical and impact testing methods. It also describes how testing protocols developed for metals can be leveraged for plastic films and laminates, and includes a thorough discussion on methods for performing optical strain analysis. Applications in transportation vehicles and packaging, including packaging for food, medical and electronics applications, sports equipment, and household appliances, are discussed. Safety, recycling and environmental aspects of thermoforming and its products complete the book.

Key Features

  • First comprehensive source of information and hands-on guide for the thermoforming of multilayered laminates
  • Covers applications across such sectors as automotive, packaging, home goods, and construction
  • Introduces new testing methods leveraging protocols used for metals


Engineers working with plastics films or products using plastic films (OEM level to the actual part manufacturer of thermoforming) in industries such as Automotive/ transportation manufacturing, Packaging, Plastics Industry, Paint Industry; Personnel involved in testing and QA of products using plastics films, and managers; Academic Institutions

Table of Contents

  • Dedication



    1. Introduction to Thermoforming

    1.1 History

    1.2 Market and Applications


    2. The Thermoforming Process

    2.1 Background

    2.2 Basic Principles of Thermoforming

    2.3 Difference between Plastic Sheets and Laminates

    2.4 Theory of Forming Process

    2.5 Forming Characteristics

    2.6 Machinery


    3. Review of Characteristics of Common Plastics for Thermoforming

    3.1 Impact of Main Variables


    4. Lamination

    4.1 Why Laminates?

    4.2 Elements of Laminates

    4.3 Typical Commercial Laminates

    4.4 Hot-Roll Lamination

    4.5 Extrusion Lamination

    4.6 Flame Lamination

    4.7 Adhesive Lamination


    5. New Developments

    5.1 Heating Technology

    5.2 Trimming Technology

    5.3 Thickness Reduction

    5.4 Pressure Forming

    5.5 Vacuum Forming

    5.6 Twin-Sheet Forming

    5.7 Reinforced-Sheet Forming

    5.8 Multilayer Sheet Forming

    5.9 Biaxial Bulge

    5.10 Biaxial Strain

    5.11 Bulge Test Models


    6. Mechanics of Materials

    6.1 Stress

    6.2 Strain

    6.3 Stress Relaxation and Creep

    6.4 Creep and Stress Relaxation Models

    6.5 Peeling

    6.6 Delamination


    7. Characterization

    7.1 Mechanical Testing

    7.2 Impact Testing

    7.3 Biaxial Bulge Testing

    7.4 Rheological Testing

    7.5 Differential Scanning Calorimetry (DSC)

    7.6 Color Test

    7.7 Specular Gloss Test


    8. Matching Material Characteristics to Commercial Thermoforming

    8.1 Packaging

    8.2 Appliances

    8.3 Bathroom

    8.4 Transportation

    8.5 Sports


    9. Safety, Recycling and Environmental Issues of Thermoforming and its Products

    9.1 Safety

    9.2 Safety Guards

    9.3 Recycling

    9.4 The Economics of Recycling

    9.5 Handling of Scrap

    9.6 Contamination

    9.7 Environmental Impact


    10. Other Processing Approaches

    10.1 Melt Extrusion

    10.2 Coextrusion

    10.3 Calendering

    10.4 Casting

    10.5 Coating


    11. Modeling of Thermoforming: A Literature Review

    11.1 Models


    12. Troubleshooting

    12.1 Thermoforming

    12.2 Hot-Roll Lamination



Product details

  • No. of pages: 352
  • Language: English
  • Copyright: © William Andrew 2013
  • Published: November 7, 2013
  • Imprint: William Andrew
  • eBook ISBN: 9781455731862

About the Author

Syed Ali Ashter

Syed Ali Ashter, Principal at Ashter Consultancy LLC., has worked on developing medical devices from concept to commercialization, and in process development. He performed post-doctoral research on next generation formable films for the automotive industry at McMaster University, and received his Ph.D. in 2008 in Plastics Engineering from University of Massachusetts Lowell. He has been on the Board of Directors of the Medical Plastics division of the Society of Plastics Engineers since 2012. He has published two books: ‘Thermoforming of Single and Multilayer Laminates’ at the end of 2013, and ‘Introduction to Bioplastics Engineering’ in 2016.

Affiliations and Expertise

Principal, Ashter Consultancy LLC., Massachusetts, USA

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