MAKROLON® Polycarbonate Fabrication Guide
Contents
1. NONE CLEARER makroLon Finishing eter 16 Jointing Planing ee II 16 Solvent Polshlmg z ce soe ues EPOR 16 is 3 3 A DER tx den 16 ocreen PININ ron raced Fender dha 16 kobe gud em e Gn 17 Paint andi INK us ie ER RU ERU CR ORE 17 Glazing Information Installation Guidelines and Procedures 18 Cleaning and 19 Product Selector Product Features us ovid t EA 20 Competitive Offsets ee eee eee 20 Warranties erasi eae tarder e Rye dod 21 Technical Information Physical Properties 22 Environmental Resistance 23 Fabricating CIRCULAR SAWS A circular saw blade with carbide teeth utilizing the triple chip tooth design is the preferred method of cutting MAKROLONe Polycarbonate Sheet Table or overhead panel saws are normally used Circular saws should be run in the speed range of 6000 8000 ft min Blades for cutting 3 32 and thicker material should have 3 5 teeth per inch The hook or rake angle should be 10 15 When sawing thin gauge MAKROLON Polycarbonate Sheet it is important to have a good supporting edge on the saw table with minimal gap between the saw blade and table supporting edge Be sure tabletops are smooth and free from projections2. 36 42 48 54 60 66 Short Dimension Inches 18 A TOUGHER NONE CLEARER makKroLon EXPANSION ALLOWANCES EDGE ENGAGEMENTS COMPARATIVE EXPANSION RATES Sheet Size 24 24 24 36 36 48 48x60 Material F Expansion nra 2 AOS 1 8x1 8 1 83 16 3 16 1 4 1 45 16 Glass 0000050 Edge 2 MAKROLON E oe 12 mie 3 4 Polycarbonate Sheet 0000875 Rabbet 4 0 116 1316 1 1 16 Aluminum 0000129 Depth Steel 0000063 Acrylic 0000410 Definition of Terms Thoroughly rinse with warm water using a soft cloth or sponge Wash with mild soap or detergent and rinse Expansion thoroughly with clean water To prevent water spots thoroughly the glazing with a chamois moist sponge Do not use abrasive cleaners Avoid cleaning in direct Robbet sunlight to prevent streaking Depth a The following cleaning agents are compatible with 777 MAKROLON Polycarbonate Sheet products when used according to the manufacturer s recommendations otal Edge Expansion a Rabbet Depth Engagement Allowance O Formula 409 O Top Job O Palmolive Liquid O Windex D with Ammonia D As a general guideline glazing systems should be Formula 409 is a registered trademark of Clorox Company designed to allow 1 16 per foot of length and width as Top Job and Joy are registered trademarks of Proctor amp Gamble the expansion In the sash Pal
3. BLOWN DOME FORMING Heat Source Clamp Frame Am Air Box m Air Inlet MAKROLON Polycarbonate Sheet Sag eee Electric ye DRAWN DOME FORMING ETETA Clamp mM Vacuum Box Vacuum Line Air Pressure 25 L HWrn Electric ty Eye Apply Vacuum TOUGHER CLEARER makroLon DRAPE FORMING O Avoid bending short tabs on wide parts warping Fam Pressure Frame may O For thicker gauge sheet use two sided heating Repeated J turning with one side heating may also achieve sufficient heat penetration l iy MAKROLON Polycarbonate O Thicker gauge sheet above 1 8 can be grooved with Mold Sheet 1 16 radius to allow sharper bends Pressure Frame d HEAT BENDING DEVICE 3 4 Transite approx MAKROLON sd Polycarbonate Mold Sheet Felt Covering for Mold Nichrome resistance wire or Calrod 6 wide type heater DRAPE FORM NG Milled groove to accept Nichrome i imately 1 16 1 8 Simple contours can be achieved by drape forming control MAKROLON Polycarbonate Sheet This method can be Polycarbonate Sheet Do not allow utilized to manufacture a part
4. GP Polycarbonate Sheet Standard MAKROLON GP Polycarbonate Sheet is backed by a limited warranty against breakage This limited warranty applies to glazing sheet installed and cleaned according to the manufacturer s recommendations If failure occurs within the warranty period the purchaser will receive a free replacement of MAKROLON Polycarbonate Sheet when the failed sheet original sales receipt and warranty are provided to Sheffield Plastics or the original distributor or dealer Sheffield Plastics reserves the right to refund the original purchase price of the sheet in lieu of a replacement sheet MAKROLON SL Polycarbonate Sheet MAKROLON SL Polycarbonate Sheet is backed by a limited warranty against loss of light transmission and excessive yellowing This limited warranty applies to glazing sheet installed and cleaned according to the manufacturer s recommendations MAKROLON AR Polycarbonate Sheet MAKROLON AR Polycarbonate Sheet is backed by a limited warranty against breakage loss of light transmission excessive yellowing and coating failure This limited warranty applies to glazing sheet installed and cleaned according to the manufacturer s recommendations If failure does occur as defined in the actual warranty the purchaser will receive a free replacement MAKROLON AR Polycarbonate Sheet when the failed sheet original sales receipt and warranty are provided to Sheffield Plastics or the original distributo
5. TUFFAK CM 2 MAKROLON CG 375 Physical attack resistant LEXGARD MPC 375 N A MAKROLON CG 500 Physical attack resistant LEXGARD MPC 500 N A MAKROLON CG 750 Physical attack resistant LEXGARD RC 750 N A Poder Bullet resistant LEXGARD MP 750 N A B bs Bullet physical attack resistant LEXGARD MP 1000 N A EDS a Bullet physical attack resistant LEXGARD SP 1250 MAKROLON WG Window Grade high impact strength Westlack Zelux MAKROLON TG Optically clear enhanced abrasion LEXAN FRA460 amp UV resistance FRA236 Lexan and Lexgard are registered trademarks of General Electric Corp Tuffak is a registered trademark of AtoHaas Light Transmission Initial LIGHT AND ENERGY TRANSMITTANCE By allowing up to 9096 of solar energy and 8896 of visible light through clear MAKROLON Polycarbonate Sheet is an excellent glazing material for applications designed to maximize solar gain In areas of solar intensity where higher shading or privacy is required tinted materials may be used Clear Bronze or Gray Gauge Visible Solar Energy Visible Solar Energy 3 327 8796 9096 5096 5896 1 8 8696 8996 5096 5896 3 16 84 88 50 58 1 4 8290 8690 5090 5890 20 NONE TOUGHER Technical Information nour Panen TYPICAL MAKROLON GP POLYCARBONATE SHEET PROPERTIES Property MAKROLON Units Test Method General Specific gravity 1 2 ASTM D 792 Water Absorption 24 hrs 0 15 ASTM D 570
6. The addition of 10 glacial acetic acid in the solvent reduces whitening 3 Thickening the solvent with polycarbonate resin or sawdust promotes slower curing and reduces whitening 4 Joint cure time is somewhat longer than acrylic Be sure to retain fixture pressure until the joint is solid Note Use extreme caution when working with solvents Adequate ventilation is essential Control exposure levels according to OSHA guidelines Obtain Material Safety Data Sheets from the solvent manufacturer Hartel Enterprises Lord Corp 12970 Branford 2000 West Grandview Blvd Pacoina CA 91221 Erie PA 16514 Tel 818 767 0861 Tel 814 868 3611 Ciba Specialty Chemicals Performance Polymers 4917 Dawn Avenue East Lansing MI 48823 Tel 800 367 8793 www loctite com NONE TOUGHER 4 NONE CLEARER maKkroLon MAKROLON POLYCARBONATE SHEET ADHESIVE GUIDE ADHESIVE JOINS MAKROLON COMMENTS COLOR 1 OR 2 APPLICATION SETUP CURE SUPPLIER SHEET TO SYSTEM METHOD TIME TIME Methylene MAKROLON Clear Solvent Clear One Flow 20 sec 48 hrs Chemical Chloride Polycarbonate Sheet High tensile 75 F Supply House strength products Acrylic Low impact resistance Weld On Series MAKROLON Various viscosities Clear One Flow 1 min 24 hrs IPS Weld On Polycarbonate Sheet offering quick bonds Butyrate Urethane Virtually Anything Clear flexible Hartel high impact bond 5hrs Enterprises Inc Ex
7. Tremco removed Rabbet should be free of burrs and of the Columbus OH proper depth to allow for expansion of the MAKROLON 800 321 7906 Polycarbonate Sheet glazing panel Gasket EPDM 60 70D 2 Carefully measure the sash opening Determine Columbus OH the appropriate edge engagement and expansion 800 321 6357 allowance from Table on next page Cut MAKROLON Tape 440 Tremco Polycarbonate Sheet to the exact size required making Beechwood OH sure cut edges are smooth and free of chips and notches 800 321 7906 3 Glaze MAKROLON Polycarbonate Sheet with the proper Gasket Tape Norrene Foam Norton Company V 2100 Urethane Granville NY 518 642 2200 Butyl Tape Isocryl 5600 Schnee Morehead Irving TX 214 438 9111 compatible sealant While smaller lites allow for the use of nonhardening oil based and acrylic latex caulks up to 24 x 24 the thermal and load movements in larger sheet sizes require high performance low modulus elastomers Such as silicones Many other glazing materials are commercially available which are compatible with MAKROLON Polycarbonate Sheet Please contact those manufacturers for their recommended products Trademate is a registered trademark of Dow Corning Corp Silpruf is a registered trademark of General Electric Company Norrene is a registered trademark of Norton Company WIND LOAD PERFORMANCE T N Qa amp o N Wind Velocity
8. fine grit sandpaper is recommended SOLVENT POLISHING In order to improve the look of saw cut edges begin by sanding the edges smooth For smoother glossy edges consider solvent polishing with MEK or methylene dichloride To prevent humidity blush after drying it may be necessary to add a small amount of a slow drying component such as diacetone alcohol or glacial acetic acid Since MAKROLON Polycarbonate Sheet has such good chemical resistance properties keep in mind that solvent polishing cannot be expected to totally eliminate sand marks from the sheet edge Note Use extreme caution when working with solvents Adequate ventilation is essential Control exposure levels according to OSHA guidelines Obtain Material Safety Data Sheets from the solvent manufacturer 16 Clearly the Right Choice HOT STAMPING MAKROLON Polycarbonate Sheet is easily decorated by hot stamping Normal operating conditions are head die temperatures 375 F dwell time 2 3 seconds at 60 psi Contact foil manufacturer for recommended application guidelines SCREEN PRINTING Standard silk screening equipment with screens of varying mesh 8x 16x regulating the amount of ink coverage on MAKROLON Polycarbonate Sheet provides excellent sign product As with all thermoplastics MAKROLON Polycarbonate Sheet must be clean and free from surface residuals prior to screening Many screeners use a prerinse of 5096 water and 5096 isopropyl alcohol
9. oven for uniform temperature Shading may also be used to control the sag of MAKROLON Polycarbonate Sheet during heating PROCEDURE O Use heavy duty metal screening to shade the major portion of the clamped sheet leaving several inches along the edges unshaded to compensate for cooler areas O Screens can be installed permanently or placed loosely above the sheet depending on how much shading is required HELPFUL HINTS O Use slow heating This is particularly important with heavier gauges in order to prevent gradient heating O Allow heat to reach uniformity at the center of the sheet O The heating rate may be reduced by lowering the heat intensity or by moving the sheet farther away from the heaters Thermoforming Troubleshooting PROBLEM POSSIBLE CAUSE A M NONE CLEARER makroLan SUGGESTED SOLUTION Bubbles or blisters Too much moisture in sheet Predry sheet for longer time period Check predry oven temperature Pinholes or surface marks Vacuum holes too large Use smaller diameter vacuum holes Mark off Mold surface too smooth Mold surface too rough Vapor hone or use extra fine emery cloth to lightly abrade mold surface Preheat mold Sheet pulls out of damping frame during forming Sheet too cold to form Heat sheet for longer time period Non uniform sag Uneven heating Check heaters Screen hot areas Incomplete part
10. requiring a simple radius of wire to contact sheet directly curvature Mold material can be wood fiberglass or aluminum covered with felt STRIP HEATING TROUBLESHOOTING PROCEDURE PROBLEM Bubbles in bent area O Predrying MAKROLON Polycarbonate Sheet may POSSIBLE CAUSE Too much heat not be necessary SUGGESTED SOLUTION Reduce temperature O Bring to forming temperature of about 300 F 320 F in PROBLEM Warpage the oven POSSIBLE CAUSE Part too wide for heat bending SUGGESTED SOLUTION Heat from both sides to provide O Remove parts and immediately place over a male mold more uniform heat penetration covered with felt PROBLEM Heating not uniform O Apply pressure until cool SUGGESTED SOLUTION Check for air drafts which may affect uniform cooling STRIP HEATING MAKROLON PROBLEM Cooling not uniform PO LYCARBONATE SHEET SUGGESTED SOLUTION Do not try to bend short Strip heating or line bending is commonly used for producing under 1 sections localized angular bends in polycarbonate Generally predrying is not required for material thicknesses of 118 or less PROBLEM Mark off POSSIBLE CAUSE Heater is contacting plastic Transite is too PROCEDURE hot Masking is not removed over sufficient ee area where heat is being applied O Remove protective masking in bend area SUGGESTED SOLUTION Lower heat source Regulate nichrome heat source to 340 F 365 F maximum O Place sheet over heat source at bend are
11. saws should be run at 2500 3000 ft min and have 8 12 teeth per inch Coarser larger tooth blades perform better with thicker gauge MAKROLON Polycarbonate Sheet Proper support of the part to be trimmed is important because vibration may induce cracking if the cut is not smooth Sanding the edge smooth after cutting is recommended BAND SAW BLADE DESIGN 1 8 12 teeth per inch BAND SAW TROUBLESHOOTING PROBLEM Melting or Gummed Edges SUGGESTED SOLUTIONS 1 Increase tooth size 2 Reduce saw speed 3 Use air to blade 4 Check blade sharpness PROBLEM Chipping SUGGESTED SOLUTIONS 1 Decrease tooth size 2 Slow down stock feed rate 8 Provide better clamping and or support to eliminate vibration 4 Check blade sharpness ROUTING Routing produces a smooth edge on MAKROLON Polycarbonate Sheet and may also be used to cut curved or irregular shapes Routers with a speed of 20 000 to 25 000 rpm are preferred Use straight fluted 2 or 3 carbide tipped or high speed steel router bits Bits should be 1 4 to 1 2 diameter for best results Use a router with at least 1 H P motor Special care must be used when routing Use proper guarding and eye protection Stock feed rates must be monitored closely Feeding MAKROLON Polycarbonate Sheet at excessive rates can cause vibration and cracking A ved NONE CLEARER makKroLOon It is important to MAKROLON Table feed the sheet Polycarbon
12. that might scratch or mar MAKROLON Polycarbonate Sheet Hold Down Blade MAKROLON zem gt Gap between saw blade and table minimize Triple Chip Alternate Tooth Design Clearly the Right Choice CIRCULAR SAW TROUBLESHOOTING PROBLEM Melting or Gummed Edges SUGGESTED SOLUTIONS 1 Increase blade tooth size Reduce saw speed Increase feed rate Use air to cool blade Use blade lubricant compatible with MAKROLON Polycarbonate Sheet 6 Inspect blade for sharpness 7 Check blade fence alignment 8 Reduce number of sheets in stack PROBLEM Chipping SUGGESTED SOLUTIONS 1 Decrease blade tooth size 2 Increase saw size 3 Provide better clamping and or support for sheet stack 4 Reduce feed rate 5 Check blade and arbor for wobble 6 Inspect blade for sharpness Router Bit Suppliers Dino Saw Company 340 Power Ave Hudson NY 12534 Tel 618 828 9942 Onsrud Libertyville IL Tel 847 362 1560 Bochco Inc Billerica MA Tel 978 667 1911 Saw Blade Suppliers Forrest Manufacturing 461 River Road Clifton NJ 07014 Tel 800 733 7111 General Saw Corp 20 Wood Ave Secaucus NJ 07094 Tel 800 772 3691 Inc 6160 Cobblestone Rd Placerville CA 95667 Tel 916 626 1986 Dino Saw Company 340 Power Ave Hudson NY 12534 Tel 618 828 9942 5 5 Band saws are useful for trimming formed parts or irregular shapes Band
13. using methods employed in fabricating other thermoplastics such as acrylic The two most common methods are needle type applicator capillary action and edge dipping Both methods rely on smooth edge preparation pressure and curing It should be noted that solvent bonding will significantly reduce the strength of polycarbonate PROCEDURE O Smaller items with flat surfaces can be bonded by placing the pieces together and applying the solvent along the edges using a needle applicator or hypodermic syringe Make sure the solvent flows along the entire joint O For bonding larger items immerse the surfaces to be joined in the solvent until the material is softened O Clamp them in position and hold until the bond is set Adhesive Suppliers Industrial Polychemical Pacer Technology Weld On Adhesives 9420 Santa Anita Ave 17109 South Main Street Rancho Cucamonga CA 91730 Gardena CA 90247 Tel 800 538 3091 Tel 800 421 2677 Dow Corning Corporation General Electric Company 3901 South Saginaw 260 Hudson River Road Midland MI 48640 Waterford NY 12188 Tel 517 496 4000 Tel 518 237 3330 14 Clearly the Right Choice NEEDLE APPLICATOR HELPFUL HINTS O Edges must be clean and free from dirt O Surfaces should be smooth and properly aligned O Apply even pressure to reduce bubbles in the bond area TECHNIQUES TO REDUCE WHITENING 1 Fabricate in a climate controlled area with low relative humidity 2
14. 360 F The heat required will be higher for more complex shapes When MAKROLON Polycarbonate Sheet reaches forming temperature uniform sag occurs The amount of sag depends on the size and thickness of the sheet A 12 x 12 x 060 sheet will sag approximately 1 A 36 x 36 x 177 sheet may sag 4 6 at the center Once uniform temperature has been achieved timers can accurately reproduce the condition and part to part consistency can be maintained PROCEDURE O Sheet thicknesses up to 177 gauge can be heated from one side Above 177 gauge two sided heating is normally required to significantly enhance productivity O Heat source is removed and heated sheet is forced over or into mold where vacuum is applied HELPFUL HINT O MAKROLON Polycarbonate Sheet sets up very quickly compared to other thermoplastics and can be removed from the mold in a short period of time Caution MAKROLON Polycarbonate Sheet remains quite hot during this cycle and care must be observed when handling finished parts O Throughout the vacuum forming process it is imperative that dust and dirt be controlled MAKROLON Polycarbonate Sheet has a static charge that attracts foreign particles which can create surface imperfections Molds also attract dust particles and should be cleaned to avoid creating surface defects Clearly the Right Choice SHADING OR SCREENING Shading is often used to balance out hot spots in an
15. MAKROLON POLY CARBONATE 5 E E T MADE WITH Clearly the Right Choice Fabrication Guide B A Bayer MaterialScience Company NONE CLEARER Curbell Plastics is a proud supplier of Sheffield materials cu BELL 1 888 CURBELL www curbellplastics com PLASTICS None Tougher None Clearer MAKROLON Polycarbonate Sheet Made with MAK for Quality and Excellence Produced from Bayer Corporation s MAKROLON polycarbonate resins Sheffield s MAKROLON Polycarbonate Sheet meets or exceeds the performance characteristics of any directly competitive product on the market today Combining innovation with a desire for excellence and state of the art manufacturing Sheffield Plastics Inc produces a wide range of polycarbonate sheet products that are unsurpassed for clarity and toughness With outstanding forming fabrication and performance characteristics None Tougher None Clearer MAKROLON Polycarbonate Sheet can be easily fabricated into products that last When you need clarity toughness and endurance be sure you choose Made with MAK In addition to supplying quality products leading technology and industry leading technical support Sheffield Plastics takes pride in having the highest rated distribution network in the industry The Sheffield Plastics team is comprised of our local distributors backed by Sheffield manufacturing and product support personnel When your application requires addit
16. Refractive Index 1 586 ASTM D 542 Mechanical Tensile Strength Yield 125 9 000 psi ASTM D 638 Tensile Strength Ultimate 9 500 psi ASTM D 638 Tensile Modulus 345 000 psi ASTM D 638 Shear Strength 6 000 psi ASTM D 732 Compressive Strength 12 500 psi ASTM D 695 Flexural Strength at 596 Strain 13 500 psi ASTM D 790 Flexural Modulus 125 345 000 psi ASTM D 790 Izod Impact Notched 125 12 16 ft Ib in of notch ASTM D 256 Rockwell Hardness 118 R Scale ASTM D 785 Gardner Impact 1 2 Diameter Dart 125 2320 in Ibs ASTM D 5420 Instrumented Impact 125 gt 45 ft lbs ASTM D 3763 Thermal Heat Deflection Temperature 264 psi 270 F ASTM D 648 Heat Deflection Temperature 68 psi 280 F ASTM D 648 Coefficient of Thermal Expansion 3 75 x 10 in in F ASTM D 696 Coefficient of Thermal Conductivity 1 35 BTU hr ft F ASTM D 177 Smoke Density 68 ASTM D 2843 Shading Coefficient Clear 125 1 02 ASHRAE Shading Coefficient Gray Bronze 125 70 ASHRAE Shading Coefficient Dark Gray 125 58 ASHRAE Brittle Temperature 200 F ASTM D 746 Flammability Horizontal Burn AEB 125 1 in ASTM D 635 Horizontal Burn ATB 125 1 min ASTM D 635 Self Ignition Temperature 1070 F ASTM D 1929 Flash Ignition Temperature 800 Mz ASTM D 1929 UL 94 Clear 2 060 V 2 UL 94 UL 94 Clear 2 250 V O UL 94 Optical Transmittance Clear 125 gt 88 ASTM D 1003 Haze Clear 125 lt 1 ASTM D 1003 Electrical Dielectric Constant 10 Hz 2 96 A
17. STM D 150 Dielectric Constant 60 Hz Be ASTM D 150 Volume Resistivity 8 2 x 10 ohm cm ASTM D 257 Dissipation Factor 60 Hz 0 0009 ASTM D 150 Dissipation Factor 1 MHz 0 010 ASTM D 150 Arc Resistance Stainless Steel Strip Electrodes 10 11 sec ASTM D 495 Tungsten Electrodes 120 sec ASTM D 495 COMPETITIVE EDGE DOCUMENTATION AND TECHNICAL SUPPORT Sheffield Plastics Inc sets rigid raw material requirements Specific product information warranty details and further for its polycarbonate resins supplied by Bayer Corporation information regarding proper fabrication and or use of These materials coupled with state of the art production and quality control technology assure that the physical properties of MAKROLON Polycarbonate Sheet will meet or exceed any directly competitive product on the market today When it s Made with Mak you really have a materials can be received by contacting your local MAKROLON Polycarbonate Sheet distributor or by visiting us at www sheffieldplastics com MAKROLON POLYCARBONATE competitive edge SHEET COMBUSTIBILITY Sheffield Plastics Inc will not be responsible for the use of this information relative to Although the least combustible glazing material actual application Users must make their own determination of its suitability for their Polycarbonate Sheet will ignite when exposed toan specific use No warranty is made for the fitness of any product and nothing herein waives any of the seller
18. a v Strip Heaters O Allow heat to soften material time depends on gauge Inc C R Clark amp Co O Remove sheet and make desired bend on wood or heavy 6160 Cobblestone Road 4407 Vineland Road D5 fabric covered aluminum fixture Placerville CA 95667 Orlando FL 32811 Tel 916 626 1986 Tel 800 676 7133 O Bend immediately polycarbonate sets up quickly Allow sheet t lin fixture rales Ine ad 2701 N Pulaski Road O Some bends may require a degree of overbending to Chicago IL 60639 achieve desired angle after sheet sets up Strip heating Tel 773 235 3307 works best for relatively short parts wide parts may warp 13 Bonding and Fastening MECHANICAL FASTENING Aluminum rivets and machine screws may be used to join MAKROLON Polycarbonate Sheet to other materials by utilizing proper attachment methods Drill oversized holes and use washers to distribute and cushion localized stress Be sure to consider differentials in expansion factors for dissimilar materials Be sure drilled holes are smooth and free from cracks Oversized Hole Resilient Washer MAKROLON polycarbonate sheet bae Resilient Washer SOLVENT BONDING Many applications for MAKROLON Polycarbonate Sheet involve fabrication of sheets to construct three dimensional shapes The most popular method is to solvent bond MAKROLON Polycarbonate Sheet solvent bonding can be achieved
19. ack except that heated sheet is billowed up and mold rises to meet it 11 A TOUGHER NONE CLEARER makroLon SHEET HEATER CLAMP pom M 8 MALE MOLD WORK TABLE VACUUM Drape forming over a male mold usually results in better material distribution and depth to diameter draw ratios HEATED SHEET MALE VACUUM MOLD Vacuum forming with snap back can reduce starting sheet size aid material distribution and minimize chill marks Le CLAMP VACUUM BOX VACUUM VACUUM DRAWS SHEET AGAINST MOLD AIR BLOWS SHEET UP Forming with billow plug is often used to produce thin wall items with depth to diameter draw ratios up to 1 5 1 Forming cont d FREE BLOWN BILLOW FORMING OF DOME This process is utilized for forming dome shapes from MAKROLON Polycarbonate Sheet The procedures and equipment are the same as vacuum forming with the exception of the mold Billow forming can be done with positive air pressure free blown or negative pressure vacuum PROCEDURE O Preheat all clamps and tooling 240 F 260 F O Predry MAKROLON Polycarbonate Sheet in air circulating oven at 250 F See page 7 for recommended drying times O Place MAKROLON Polycarbonate Sheet in clamping frame of thermoforming machine O Heat sheet until uniform sag occurs 840 F 380 F O Remove heat source O Lower pressure box to seal air supply pressure O Apply air pressure Initial
20. adius based upon the sheet thickness As a guideline the material can be radiused to 100 times the thickness R T x100 COLD BEND RADII Sheet Thickness T Minimum Radius R 1 8 12 5 3 16 18 77 1 4 25 0 Note MAKROLON AR Polycarbonate Sheet is recommended for flat glazing only DRYING TIME HOURS THICKNESS 250 F 180 F 093 4 8 118 6 14 150 8 20 ATT 12 30 236 24 50 Note MAKROLON AR Polycarbonate Sheet is recommended for flat glazing only A ved NONE CLEARER makroLon THERMOFORMING MAKROLON Polycarbonate Sheet can be thermoformed on standard equipment Vacuum forming free blown forming and line bending are the most extensively used processes While most standard forming techniques can be used critical process modifications specific to polycarbonate are necessary to ensure uniform and repeatable formed parts PREDRYING MAKROLON POLYCARBONATE SHEET MAKROLON Polycarbonate Sheet must be dried before thermoforming because polycarbonate absorbs moisture at a high rate Trapped moisture forms vapor above 250 F and the vapor expansion creates bubbles in the sheet Sheets of MAKROLON Polycarbonate sheet should be placed in a dehumidifying air circulating oven for predrying Temperature should be 250 F and monitored with controls Recommended predrying time periods are shown below Be cautious Polycarbonate sheet begins absorbing moisture immediatel
21. air pressure is high and as dome is created air pressure is reduced O When overall height is achieved maintain positive air pressure until part cools O Be sure air source is properly filtered and uniformly dispersed for even formation of dome O Utilize electric eye designs or microswitches to assure consistent product O When dome reaches electric eye set height The eye controls air pressure through a solenoid valve to control cooling O Remove and trim FREE DRAWN VACUUM DOME FORMING Follow steps involved in vacuum thermoforming including predrying PROCEDURE O Place sheet in clamping frame of thermoforming machine O Heat sheet until uniform sag occurs 340 F 380 F O Remove heat source O Apply vacuum seal box and apply vacuum pressure O Use electric eye or microswitch to assure consistency of depth of dome O Retain small amount of vacuum pressure until dome sets up O Remove and trim 12 Clearly the Right Choice REGISTRATION FORMING MAKROLON Polycarbonate Sheet is suitable for registration vacuum forming Because the material is extruded it is important to orient the sheet so that each part is screened and formed in the same direction each time Material should be specially ordered for this application Dimensional stability tests indicate MAKROLON Polycarbonate Sheet in free form releases stress about 2 496 in the direction of extrusion and 196 across the extrusion web
22. ate Sheet Y against the rotation of the router bit and to provide a fence for sizing when making straight cuts Feed Direction fe Router Bit Fence LASER CUTTING MAKROLON Polycarbonate Sheet can be cut using industrial cutting lasers Edges may become amber or brown when laser cutting For information on laser cutting equipment and part cutting services contact the manufacturer of your equipment or the suppliers listed on this page SHEARING MAKROLON Polycarbonate Sheet may be sheared using a conventional sheet metal power shear It is important to adjust the top blade clearance in relationship to the bed blade A clearance of 001 is desirable to avoid a rough edge cut Shear single sheets only 20 1 05 Bed Blade Laser Cutting Equipment Suppliers Coherent General Laser Machine Inc Picker Road 500 Laser Drive Sturbridge MA 01566 Somerset WI 54025 Tel 508 347 2681 Tel 715 247 3285 Laser Cut Parts Laser Engineering Inc Laser Machine Inc 444 North York Road 500 Laser Drive Elmhurst IL 60126 Somerset 54025 Tel 630 530 0500 Tel 715 247 3285 Fabricating cont d DIE CUTTING Die cutting MAKROLON Polycarbonate Sheet in gauges up to 080 thick is normally achieved utilizing the following steps Steel rule dies mounted in a press provide good results The shear strength of MAKROLON Po
23. aylat Corporation 716 South Columbus Avenue Mt Vernon NY 10550 Tel 914 699 3030 Wyandotte Paint Products Co 3295 River Exchange Drive Suite 500 Norcross GA 30092 Tel 800 233 2303 17 A M NONE CLEARER makroLan Foilmark 40 Melville Park Road Melville NY 11747 Tel BOO 645 9177 NAZ DAR Company 1087 N Northbranch Street Chicago IL 60622 Tel BOO 736 7636 Red Spot Paint amp Varnish Co Inc 1016 East Columbia Street Evansville IN 47711 Tel BOO 457 3544 Mathews Paint Company 8201 100 Street Kenosha WI 53142 Tel 800 323 6593 Glazing Information Clearly the Right Choice INSTALLATION GUIDELINES RECOMMENDED SEALANTS GASKETS AND TAPES MAKROLONe Polycarbonate Sheet may be installed using wet or dry glazing systems However Sheffield warns Product Product Manufacturer against the use of PVC gasketing The material may also Type Name be used for double glazing or over glazing applications for Silicone Dow 795 Dow Corning Corp added insulation and security Maintain adequate separation Dow 999 Midland MI between the glazing panels to prevent touching during high Tradematee 517 496 4000 HON ery IC Silicone General Electric Co ur die PROCEDURES Construction Waterford NY Clean sash and prime if necessary For replacement 1200 800 255 8886 glazing make sure all old sealant and projections are Silicone Spectrem
24. cellent peel Clear Two Flow 8 hrs 150 F strength 75 F days Formulated Excellent shear 75 F Systems Group strength RTV Silicone Metal Plastic Wood Excellent heat Various One Tubes Caulkers 60 min 24 hrs Dow Corning resistance Colors 75 F Good thermal GE Silicones expansion TRANSFER TAPE BONDING WELDING Achieving a strong edge bond using solvents on thin gauge thermoplastics is extremely difficult due to the reduced size of the bond area Structural bonding of thin gauge MAKROLON Polycarbonate Sheet can be accomplished however by utilizing acrylic based transfer tapes along with slight design modifications PROCEDURE O Bend a small return on the appropriate part to be fastened approximately the width of the transfer tape O Clean tape contact areas with 50 50 isopropyl alcohol water mixture O Apply transfer tape to the return O Remove tape masking and press the part into place HELPFUL HINTS O Rolling the bonded area with a small wood or rubber roller improves bond strength O A nonstick slip sheet is useful for proper positioning of large or hard to handle parts O Peel strength of long lineal bonded areas can be increased with the addition of a mechanical fastener at both ends of the bond 15 While mechanical fastening and solvent bonding are the most often recommended methods for joining plastics another alternative is welding Ultrasonic radio frequency and spin weldi
25. e to the fact that if the mold surface is too smooth air entrapment can occur creating mark off For best results use fine hand sanding on the surfaces Sanding provides tiny channels for air evacuation to prevent air entrapment This may have to be repeated on long production runs as the sanded finish smoothes out from extended use When constructing the mold mold shrinkage should be a design consideration Shrinkage for MAKROLON Polycarbonate Sheet is 005 007 The heating cooling cycle and the type of vacuum forming equipment will also influence results MOLD SHRINKAGE 3 00 Part MOLD MATERIALS AND MOLD DESIGN MAKROLON Polycarbonate Sheet allows the use of a variety of mold materials wood filled and unfilled polyesters epoxies and metals Molds for vacuum forming need to take only 14 psi so there is little wear on the tooling with low pressure of the material against the mold surface 10 Clearly the Right Choice TYPICAL MOLD MATERIALS THERMAL CONDUCTIVITY PROPERTIES Material Heat Transfer K Value Rate Factor btu hr sf f ft Aluminum 6190 130 Steel 1238 26 Aluminum filled epoxy 24 47 52 87 Plaster of Paris 8 29 17 Epoxy 6 24 13 Wood maple 4 48 09 MOLD DESIGN Draft Angles Minimum 5 7 or greater for ease of part removal from the mold Radii and Fillets Use generous radii wherever possible for more uniform walls and greater rigidity On female toolin
26. formation detail Sheet too cold Inadequate vacuum Heat sheet for longer time period Check vacuum system for leakage Increase vacuum Webbing Sheet too hot Improper mold spacing Reduce heating cycle Redesign mold Use mechanical assist bridging Brown Machine Thermoforming Machines Plasti Vac Inc Division John Brown Plastics 214 Dalton Avenue 330 North Ross Street P O Box 5543 Beaverton MI 48612 Charlotte NC 28206 Tel 517 435 7744 Tel 800 438 4139 Shuman Co P O Box 240906 Charlotte NC 28244 Tel 704 525 9980 Drying Ovens Grieve Corporation 500 Hart Road Round Lake IL 60073 Tel 847 546 8225 Forming cont d MOLDS In general male molds are more suitable for vacuum forming However other factors such as part size finish and shape dictate mold design Choice of mold materials should be determined by considering the length of the production run For optimum cost effectiveness use the least expensive material that will take the entire run It is evident that thermal transfer is much more efficient with aluminum than wood Wood however can be utilized for Short run projects Polycarbonate Sheet reproduces mold surface finish accurately even to the point of replicating wood grain in a smooth wood mold Sometimes it is desirable to reduce the polish on a steel or aluminum mold by utilizing a vapor hone or bead blast This is du
27. g use permanent corner fillets Vacuum Holes In order to form the sheet as rapidly as possible use sufficient holes for fast evacuation of air from between the sheet and the mold In female molds use air evacuation holes at all deep draw areas especially around the mold perimeter where the sheet will be drawn last HELPFUL HINTS O Keep the diameter of the holes small approximately 1 64 1 32 diameter to avoid marking on the sheet Long thin slots may be designed for air evacuation in female tooling O Use vapor honed or fine sanded finishes O Avoid sharp corners to minimize stress O Avoid highly polished surfaces that can cause mark off O Always preheat mold Cold molds can create surface defects and or warped parts O If mold temperature becomes too high during thermo forming runs MAKROLON Polycarbonate Sheet could stick to the mold It is recommended that the mold temperature not exceed 260 F FORMING GUIDELINES Sheet Temperature Typical 340 F 380 F Optimum 350 F 360 F Mold Temperature 210 F 260 F FEMALE MOLD VACUUM Straight vacuum forming in a female mold is recommended for low profile parts where deep draw is not a requirement PLUG FORCE HEATED SHEET VACUUM Thinning of material in deep mold cavities can be overcome by use of plug assists designed for fast penetration HEATED SHEET AIR ENTERING VACUUM APPLIED Air slip forming is similar to vacuum snap b
28. ional assistance please contact our team of dedicated professionals who are always ready to assist you at 800 254 1707 Contents Fabricating SAWIN a paaa erae 4 ROUINO e ee E a E E A n 5 diabe sabadan d 5 kaser CUNO aispa PPS 5 DIG CUIU Rat 6 eun oxi RR dee EREA 6 Forming Brake Bending RR Re en 7 Cold Bending scream remm reete s 7 MNEMMOTONMING iud 7 PRECIVING cca ca deo he e e e ERR 7 Forming Equipment 7 IHeaters vues iod ESRB BEER eats 7 Heating Cycle stand ddan haven CA Re eb Sex 8 Shading or 8 Troubleshooting s sos eget eto esce n ce 9 MoldS 4 eed eee ae ER 10 Mold Desigm eb vee vate ESO PE DG RE Rew ea Ps 10 Free Blown Billow Forming of Dome 12 Free Drawn Vacuum Dome Forming 12 F gistratiori FORMING s 2 ii T dead Raa 12 Drape Formihg ee Raven dans hawk awe 13 Heating eari sarrada bat Ret San eh ed ek Set big 13 Bonding Fastening Mechanical Fastening 14 Solvent Bonding srasni uirar airerik eee 14 Transfer Tape Bonding 15 WENI tx ea tette Cen Re TR ROM Rn 15 A M
29. lycarbonate Sheet is 10 000 psi which is appropriate for die cutting methods Calculating the required press tonnage to cut MAKROLON Polycarbonate Sheet F PxA 2 000 F Required force in tonnage of the press P 10 000 psi Shear strength of MAKROLON Polycarbonate Sheet A The sectional area to be cut Example Die cut 12 x 20 x 030 thick rectangle Total length of cut 20 20 12 1222 64 Shear area Total length x thickness 030 or 64 x 030 21 92 ir Required force P 10 000 psi F PxA _ 10 000 psi x 1 92 in 2000 2 000 Ibs one Press tonnage PT 9 6 Use 3 PT 0423 thick steel to fabricate steel rule die Flush or center bevel ground rule provides a clean cut Facet ground steel rule is used to cut thicker gauge MAKROLON Polycarbonate Sheet above 060 Be sure platens are parallel and that the backup pad is in good condition Backup pads can be made from a wide variety of materials such as nylon HDPE etc i i Upper Press Platen Steel cd Plywood Rule Foam Lower Press Platen HUDDOF MAKROLON Polycarbonate Sheet Backup Pad ie Reversed DRILLING MAKROLON Polycarbonate Sheet is easily drilled using ordinary high speed steel drill bits Clearly the Right Choice Regulate pressure and speed until a continuous spiraling chip is observed Use air or water as a coolant if required Using c
30. molive is a registered trademark of Colgate Palmolive Windex D is a registered trademark of Drackett Products Company Product Selector Clearly the Right Choice Product Features MAKROLON MAKROLON MAKROLON MAKROLON MAKROLON Privacy MAKROLON MAKROLON GP SN AR SL SunLife FI Patterns CG HYGARD Superior Impact Strength Enhanced UV Resistance Forced Entry Protection UL 972 N A Enhanced Abrasion Resistance Thermoformable Cold Formable Patterned Sheet t Flame Inhibiting Bullet Resistant UL 752 Physical Attack Resistant SN Polycarbonate Sheet is available with a matte finish MAKROLON SL Polycarbonate Sheet is UL 48 Certified COMPETITIVE OFF SETS MAKROLON Grade Description GE Grade AtoHaas Grade MAKROLON GP General purpose grade for fabrication LEXAN 9030 9034 TUFFAK A and glazing DL 4630 DL 4634 MAKROLON GP Matte Matte texture for privacy glazing N A N A MAKROLON GP Pebble X Pebble patterns for privacy glazing LEXAN 90318 P A G TUFFAK A P 66 MAKROLON FD FDA compliant material LEXAN 9440 TUFFAK T MAKROLON FI Flame inhibiting grade LEXAN 9600 N A FI Flame inhibiting LEXAN 1200 TUFFAK FI 8 MAKROLON SL Thermoformable enhanced UV resistance LEXAN SG 100 TUFFAK XL MAKROLON AR Abrasion amp UV resistance LEXAN MarGard
31. ng have proven to be appropriate Contact manufacturers of ultrasonic welding equipment for recommendations on section and joint design Transfer Tape Suppliers 3M Industrial Specialties Division 3M Center Bldg 220 7E 01 St Paul MN 55144 1000 Tel 800 227 5085 Ultrasonic Welding Equipment Vinton Inc 1001 Lehigh Station Road Henrietta NY 14467 9311 Tel 716 359 3100 Norton Performance Plastics 1 Sealant Park Granville NY 12832 Tel 518 642 2200 Branson Ultrasonics Corp 41 Eagle Road Danbury CT 06813 1961 Tel 203 796 0400 Finishing SANDING MAKROLON Polycarbonate Sheet can be sanded using both wet and dry techniques Gumming can result from dry sanding Wet sanding produces a smooth finish In both instances the part will require further finishing in order to restore its high gloss MAKROLON Polycarbonate Sheet can also be buffed using a 2 wheel system The first wheel uses a buffing compound to remove shallow scratches The second buffing wheel is used for restoring the gloss JOINTING PLANING A standard woodworking jointer planer is an excellent edge finishing machine for MAKROLON Polycarbonate Sheet Blades must be carbide or high speed steel Avoid removal of too much stock on each pass 1 64 or less stock removal normally yields the cleanest edge Trying to remove too much material results in a rough edge or cracking of the sheet If smoother edges are required wet sanding with
32. nzoic Acid Chloride Ethylene Chlorohydrin Phosphorus Hydroxy Xylene MAKROLON POLYCARBONATE SHEET IS DISSOLVED BY Chloroform Cresol Dioxane Ethylene Dichloride Methylene Chloride Pyridine EFFECTS OF MOISTURE ON IMAKROLON POLYCARBONATE SHEET MAKROLON Polycarbonate Sheet has good resistance to water Polycarbonate Sheet to repeated steam cleaning or dishwashing up to approximately 150 F Above this temperature the effect of can create hydraulic crazing The result can be a clouding of the moisture is time temperature related Exposing MAKROLON surface and ultimately a loss of physical strength properties 22 Made with MAK None Tougher None Clearer MAKROLON Polycarbonate Sheet BROAD RANGE OF PRODUCTS FOR THE MOST DEMANDING APPLICATIONS From lofty barrel vault skylights exposed to extreme sunlight to street level signs that require resistance to graffiti and vandalism from precision machined parts to the simple toughness of domed playground windows there is a Polycarbonate Sheet product that s right for your application Ensuring optimum transparent sheet performance MAKROLON HYGARD Laminates offer unsurpassed protection from ballistic and physical attack in bullet resisting and containment glazing applications For detailed product or limited warranty information on any Sheffield Plastics sheet product please call 800 254 1707 or visit our web site at www sheffieldplastics com MAKROLON
33. r or dealer Sheffield Plastics reserves the right to refund the original purchase price of the sheet in lieu of a replacement sheet MAKROLON HYGARD LAMINATES All MAKROLON HYGARD laminated products are backed by a limited warranty against structural delamination coating failure loss of light transmission and excessive yellowing This limited warranty does not apply to product that has been physically or ballistically attacked or damaged nor does it apply to improperly fabricated or maintained material Curbell Plastics is a proud supplier of Sheffield materials CURBELL 1 888 CURBELL PLASTICS urbellplastics com LASTI www MAKROLON Polycarbonate Sheet is Clearly the Right Choice for Any Application For More Information Please Contact Sheffield Plastics Inc Customer Service Department Phone 800 254 1707 FAX 800 457 3553 www sheffieldplastics com E mail info sheffieldplastics com Sheffield Plastics Inc A pagen Bayer MaterialScience Company 119 Salisbury Road Sheffield MA 01257 800 254 1707 Fax 800 457 3553 www sheffieldplastics com E mail info sheffieldplastics com NONE TOUGHER N wone tigane 11775 ACCREDITED Copyright Sheffield Plastics Inc 2003 Rev 5 05 Printed in USA MAKROLON HYGARDOG is a registered trademark of Sheffield Plastics Inc MAKROLONG is a registered trademark of Bayer Corp MAKFABGUIDE5 05
34. s conditions of sale ignition source over 800 F 21 Environmental Resistance of MAKROLON Polycarbonate Sheet MAKROLON POLYCARBONATE SHEET IS RESISTANT AT 70 F AND 0 STRAIN TO CHEMICALS Amyl Alcohol Chromic Acid 2096 Lactic Acid 2096 Potassium Bromate Sodium Chloride Aluminum Chloride Citric Acid 4096 Magnesium Chloride Potassium Bromide Sodium Hypochlorite Aluminum Sulfate Copper Chloride Magnesium Sulfate Potassium Nitrate Sodium Sulfate Ammonium Chloride Copper Sulfate Manganese Sulfate Potassium Perchlorate Stannous Chloride Ammonium Nitrate Formic Acid 10 Mercuric Chloride Potassium Permanganate Sulfur Ammonium Sulfate Formalin 30 Nickel Sulfate Potassium Persulfate Sulfuric Acid 10 Antimony Trichloride Glycerine Nitric Acid 10 Potassium Sulfate Sulfuric Acid 50 Arsenic Acid Heptane Nitric Acid 20 Silicone Oil Tartaric Acid 30 Butyl Alcohol Hydrochloric Acid 10 Oleic Acid Silver Nitrate Zinc Chloride Calcium Nitrate Hydrogen Peroxide 80 acid Sodium Bicarbonate Zinc Sulfate Chlorinated Lime Paste Hydrofluoric Acid 10 Pentane Sodium Bisulfate Chrome Alum Isopropanol Phosphoric Acid 10 Sodium Carbonate Sulfuric Acid at 196 attacks polycarbonate sheet COMMON HOUSEHOLD MATERIALS MAKROLON POLYCARBONATE IS RESISTANT TO PETROLEUM PRODUCTS MAKROLON POLYCARBONATE SHEET IS RESISTANT TO CHEMICALS Compressor Oil Spindle Oil Diesel Oil Transformer Oil Borax Joy Liq
35. to clean the surface of MAKROLON Polycarbonate Sheet Be sure to use soft nonabrasive cloths when cleaning to avoid scratching MAKROLON Polycarbonate Sheet lonized air also provides a good method for removing lint and dust After screening separate sheets on a drying rack until ink is completely dry DO NOT pack sheets for shipment until inks are dry UV cure inks can be used with heavy gauge MAKROLON Polycarbonate Sheet but intense or prolonged UV may have a damaging effect on thin gauges It is not recommended for MAKROLON Polycarbonate Sheet under 060 gauge as some loss of physical properties occurs PAINTING Many paint systems are available for MAKROLON Polycarbonate Sheet As with screen printing it is important that the surface of the MAKROLON Polycarbonate Sheet be clean and free of surface residuals prior to painting Many painters use a mixture of 50 water and 50 isopropyl alcohol to clean the surface of the sheet Be sure to dry thoroughly prior to painting Use a soft nonabrasive cloth or sponge to avoid scratching MAKROLON Polycarbonate Sheet Conventional spray spray masked roller coat and brush are common application methods Hot Stamping Foil Suppliers Transfer Print Foils Inc 9 Cotters Lane East Brunswick NJ 08816 Tel 908 238 1800 800 235 3645 Crown Leaf Inc 91 Illinois Ave Paterson NJ 07503 Tel 800 631 3831 Avoid using paints containing toluene xylene or solvents that will cra
36. uid Detergent Rum Kerosene Vacuum Pump Cocoa Insulating Tape Salad Oil Refined Oil Cement Linseed Oil Salt Solution 10 Note Elevated temperature and or strain significantly alters Chocolate Liquor Soap Soft Hard Cod Liver Oil Milk Table Vineaar resistance to industrial petroleum products Coates ene Vitel Tincture of lodine 5 LIMITED RESISTANCE AT 70 F AND 0 STRAIN Coffee Mustard Tomato Juice Detergents Olive Oil Vodka Antifreeze Hydrochloric Acid conc Fish Oil Onions Washing Soap Calcium Chloride Milk or Lime Fruit Syrup Orange Juice Water Oyclohexanol Nitric Acid conc Grapefruit Juice Paraffin Oil Wine Ethylene Glycol Sulfuric Acid conc Gypsum Rapeseed Oil MAKROLON POLYCARBONATE SHEET IS NOT RESISTANT TO CHEMICALS Acetaldehyde Benzyl Alcohol Chlorobenzene Formic Acid conc Phosphorus Trichloride Acetic Acid conc Brake Fluid Chlorothene Freon refrigerant propellant Proplonic Acid Acetone Bromobenzene Cutting Oils Gasoline Sodium Sulfide Acrylonitrile Butylic Acid Cyclo Hexanone Lacquer Thinner Sodium Hydroxide Ammonia Carbon Tetrachloride Cyclohexene Methyl Alcohol Sodium Nitrate Ammonium Fluoride Carbon Disulfide Dimethyl Formamide Nitrobenzene Tetrahydronaphthalene Ammonium Hydroxide Carbolic Acid Ethane Tetrachloride Nitrocellulose Lacquer Thiophene Ammonium Sulfide Caustic Potash Sol 5 Ethylamine Ozone Toluene Benzene Caustic Soda Sol 6 Ethyl Ether Phenol Turpentine Be
37. utting oils may cause crazing Be extremely careful if using taps or self tapping screws tapping creates notches that can result in stress cracks because polycarbonate is a notch sensitive material like most clear plastics Recommended drill speed is 350 1750 rpm CROSS SECTION BLADE GRINDS PEN 020 102 157 A 4h 30 s j 084 i 042 p Facet Center Side Bevel Bevel Bevel DRILL BIT DESIGN 90 188 included cutting lip angle m x Clearance angle 4 0 5 negative rake Hole Dia Drill Speed RPM 1 8 1750 1 4 1000 1500 1 2 350 500 Die Cutting Equipment Suppliers National Steel Rule Die Co 3580 Lightner Boulevard Vandalia OH 45377 Tel 937 667 3515 937 667 8407 Specialty Drill Bit Suppliers Craftics Inc 2701 N Pulaski Road Chicago IL 60639 Tel 773 235 3307 Atlas Die Inc 2000 Middlebury Street Elkhart IN 46516 Tel 219 295 0050 FTM Inc 6160 Cobblestone Road Placerville CA 95667 Tel 916 626 1986 Forming BRAKE BENDING MAKROLON Polycarbonate Sheet can be brake bent to 90 angles in gauges lt 100 Attempts at bending heavier gauges can result in cracks or breakage at the time of bending or later due to high levels of stress in the bend area For this reason strip heat bending is recommended on all gauges 118 COLD BENDING MAKROLON GP and MAKROLON SL Polycarbonate Sheets may be cold bent with the minimum r
38. y upon removal from the predrying oven The rate of absorption is dependent upon the ambient dew point For this reason it is crucial to transfer the sheet directly to the forming machine as quickly as possible FORMING EQUIPMENT The thermoforming machine should be capable of generating and maintaining a vacuum of 20 in Hg pressure throughout the thermoforming cycle Vacuum forming machines with infrared heating elements perform well for MAKROLON Polycarbonate Sheet forming Rotary and shuttle designs with automatic or semi automatic controls are most suitable Key features of this type for equipment are timer control accuracy uniform heating Sources and sufficient vacuum power Single sided heating has proven effective for MAKROLON Polycarbonate Sheet in gauges up to 177 For thicknesses above 177 it is recommended that dual sided heating ovens be used for effective radiation penetration HEATERS Infrared cal rod coiled nichrome or ceramic heating elements provide the best heating sources Gas fired heaters or convection ovens are not normally used with polycarbonate Uniform heating of the sheet is critical Radiation absorption graphs for polycarbonate are available These graphs help match the emissivity of the heating element with the sheet for the most efficient heat penetration Forming cont d HEATING CYCLE Heating MAKROLON Polycarbonate Sheet for vacuum forming requires heat penetration to achieve a 350 F to
39. ze MAKROLON Polycarbonate Sheet Be careful when using the paper masking for the design Sharp knives can notch MAKROLON Polycarbonate Sheet and allow crazing to occur Be sure not to allow razor knives to penetrate the MAKROLON Polycarbonate Sheet when cutting through masking paper Screen Print Ink Suppliers Summit Screening 201 East 16th Avenue North Kansas City MO 64116 Tel BOO 736 5959 A number of companies market paint systems for MAKROLON Polycarbonate Sheet and provide technical advice on application PAINT AND INK REMOVAL Use caution when removing overspray or drips Be sure that the solvent will not attack and craze polycarbonate Isopropyl alcohol VM amp P or similar solvents have been successfully used Be sure to rinse with clear water after solvent application Do not use scrapers blades knives etc as they will scratch MAKROLON Polycarbonate Sheet Always test a small area and observe possible attack before subjecting large sheet to solvent NOTES ON MAKROLON AR POLYCARBONATE SHEET Coated sides of MAKROLON AR Polycarbonate Sheet cannot be painted because of the abrasion resistant coating However sheet that is only coated on one side MAKROLON AR 1 Polycarbonate Sheet can be reverse screened on the uncoated side using standard painting techniques for polycarbonate This material is an excellent choice for durable graphics applications in high traffic areas Paint Suppliers Spr
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