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8065 Sheff 2c Fab bk Fabrication Guide
MAKROLON
POLYCARBONATE SHEET
MAKROLON
®
POLYCARBONATE SHEET MAKROLON
®
POLYCARBONATE SHEET:
YOU CAN'T FIND A TOUGHER
POLYCARBONATE SHEET
Sheffield Plastics produces
consistent, high-quality polycar-
bonate sheet under the
MAKROLON
®
polycarbonate
sheet trade name. Forming and
fabrication characteristics and
techniques are generally
comparable to those of other
commercial polycarbonate
sheet products.
THE SHEFFIELD EDGE
Founded in 1949, Sheffield
Plastics Inc. is a world leader in
the extrusion of high-quality,
high-performance sheet
plastics. With two production
facilities and corporate
headquarters located in
Sheffield, MA, and a
nationwide distribution system,
Sheffield Plastics manufactures
a wide range of polycarbonate
sheet products under the
MAKROLON
®
polycarbonate
sheet brand name. CONTENTS
Page
Fabricating
Sawing ...................................................................................................................................................................
3
Routing ...................................................................................................................................................................
4
Shearing .................................................................................................................................................................
4
Laser Cutting .........................................................................................................................................................
4
Die Cutting .............................................................................................................................................................
5
Drilling ....................................................................................................................................................................
5
Forming
Brake Bending ........................................................................................................................................................ 6
Cold Bending ........................................................................................................................................................ 6
Thermoforming .....................................................................................................................................................
6
Predrying ................................................................................................................................................................
6
Forming Equipment ..............................................................................................................................................
6
Heaters ...................................................................................................................................................................
6
Heating Cycle .......................................................................................................................................................
7
Shading or Screening ...........................................................................................................................................
7
Troubleshooting .................................................................................................................................................
8
Molds ...................................................................................................................................................................... 9
Mold Design ..........................................................................................................................................................
9
Free Blown Billow Forming of Dome ................................................................................................................... 11
Free Drawn Vacuum Dome Forming ................................................................................................................. 11
Registration Forming ............................................................................................................................................. 11
Drape Forming ...................................................................................................................................................... 12
Strip Heating ......................................................................................................................................................... 12
Bonding/Fastening
Mechanical Fastening ......................................................................................................................................... 13
Solvent Bonding ................................................................................................................................................... 13
Transfer Tape Bonding ......................................................................................................................................... 14
Welding ................................................................................................................................................................. 14
Finishing
Sanding .................................................................................................................................................................. 15
Jointing-Planing .................................................................................................................................................... 15
Solvent Polishing ................................................................................................................................................... 15
Hot Stamping ........................................................................................................................................................ 15
Screen Printing ...................................................................................................................................................... 15
Painting ................................................................................................................................................................. 16
Paint and Ink Removal ......................................................................................................................................... 16
Glazing Information
Installation Guidelines and Procedures ............................................................................................................. 17
Cleaning and Maintenance ............................................................................................................................... 18
Product Selector
Product Features .................................................................................................................................................. 19
Competitive Offsets ............................................................................................................................................. 19
Warranties ............................................................................................................................................................
20
Technical Information
Physical Properties ............................................................................................................................................ 21
Environmental Resistance .............................................................................................................................. 22
2 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
Dino Saw Company
340 Power Ave.
Hudson, NY 12534
Tel: (518) 828-9942
FTM, Inc.
6160 Cobblestone Rd.
Placerville, CA 95667
Tel: (916) 626-1986
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 projections that might
scratch or mar MAKROLON
polycarbonate sheet.
CIRCULAR SAW TROUBLESHOOTING
PROBLEM: Melting or Gummed Edges
SUGGESTED SOLUTIONS:
1. Increase blade tooth size
2. Reduce saw speed
3. Increase feed rate
4. Use air to cool blade
5. 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
3
Gap between
saw blade and
table - minimize
Blade
MAKROLON
®
Hold Down
Fence
Triple Chip Alternate
Tooth