Punching Station of Thermoforming Moulds

Stacking Station of Thermoforming Moulds

The second processing station of 3-Station Thermoforming Moulds (FCS), and the third processing station of 4-Station Thermoforming Moulds (FPCS) is Cutting Station. 

Top Part of Cutting Station of a Thermoforming Mould Swimming / Floating / Self Aliging Cutters	Bottom Part of Cutting Station of a Thermoforming Mould Counter Cutting / Anvil Plate

• The cutters can move on two sides.before the cutting station closes, and cutters get in to contact with the sheet, integrated centering pins on cutter templates do align the cutter with the aid of reference centering points on the sheet surface; thus a perfect precision cutting of the product is achieved. 
• Cutters used in thermoforming process are manufactured from the most known brands' proven models that the thermoforming market knows well with their quality, and long lasting service life. 
• A hard surface that will provide perfect cutting for a very long time is obtained by passing the cutter counter part / anvil plate through a precise heat treatment process. If the product permits, both surfaces of anvil plate is made simetrical, thus the cutting station's service life of the thermoforming mould is almost doubled before the time comes for a regenerative grinding.
• Cutter template installation on the cutting station is made so simple that eliminates the necessity of qualified technician during changing dull cutters. Without loosing time for the change process, one changes the cutter just by uninstalling the dull one through two fixing bolt, and installing back the new one through fixing the same two bolts, that's it, and continue to run! No need to stop the machine for uninstatlling the cutting station out of the machine for cutter renewals anymore!

Forming is the first process in a thermoforming cycle. The sheet material, be it PET or PP, is softened by applying heat in order to be able to get the shape of the designed final product by stretching and sticking to a surface by applying vacuum.

The moulds are made of special aluminum alloy to provide fast cooling with the aid of circulating water around the exterior chamber of forming cavity.    

3D modelling of the moulds with necessary shrinking tolerances allready applied thanks to our expertise and experienceare are then passed and processed on CNC Milling Machines with utmost precision. 

When designing the thermoforming mould

Standard Product Dimensions

When giving the external dimensions to a design European and American Standard packing boxes are taken into consideration. The final product should fit inside these standard boxes appropriately.  
Even customer gives an intermediate height product or design of a certain product family, Yeteka checks the market standard sizes and designs the mould with the maximum depth cavity, and with the height inserts to provide the requested depths of customer. The mould is delivered to customer ready to adopt the maximum depth easily. 

 

Each Forming Cavity in an Independent Unit!

 When manufacturing moulds capable of using for producing variable depths of final product, the mould is not processed on a single metal block. Eventough this approach increases the cost and workmanship, customer's benefit is considered and each cavity of forming station is manufactured from separate pieces. Different depths of the same product group are achieved with the aid of inserts. (In the figure above for a product depth / height of 105, 75 and 58 mm H105, H75 and H58 inserts are given respectively. Thanks to this feature customer customer does not need to buy and store one forming mould for different heightsjust needs to order inserts to have variable heights of products from a single forming station. On the other hand this feature also decreases the costs for renowation / maintenance in case of a physical damage in any of the forming cavities during it's entire service life.
  

Change the Height Even Without Uninstalling the Thermoforming Mould from Machine!

To shift from one height to another can be achieved just in 5 - 10 minutes of time; neither take the mould out from the forming stations fixing table, nor uninstall the mould in to it's components.

• The functional Cliche covering the insert fixing bolts, can be used either for stamping company Logo, Product details on the final product, or in terms of OEM Production similar details / logo of any of your customer. Thus the physical labels on any product can be easily customised with a very minor cost issue.

    

• The appropriate shrinking tolerances are given considering material type, dimensions of the product to be produced, and thickness. Plug Assists, assisting to the sheet during final form taking process, to achieve an even material distribution along the walls, are manufactured from a special thermoplastic resin that does not trace the sheet or looses it's luster; and when compared to other resins used for the same purpose, it serves more long times without burning or getting black.

• Thanks to the dead air volume discharge system integrated inside the mould production speed will be increased thus a saving both from workmanship and energy is achieved. According to the theorotical calculations the saving amount can be 3~10% from workmanship and energy. 

 

•  Mould cavities are arranged in such a way to to get optimum benefit from the sheet to be formed. 

• Precision workmanship is carried out to process the vaccum holes to get the shape as close as to the design.

• Ease of installing and un-installing for the whole thermoforming mould is a principle that we always keep in mind.