Fabricating and forming sheet - and forming sheet ... These include circular saws, band saws, saber saws, jigsaws, hacksaws, or handsaws. However, circular saws and band

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  • Fabricating and forming sheet

    Durability, Sustainability, Flexibility

  • Contents

    Fabricating and forming sheet 1

    Generalhealthandsafetyprecautions 1

    Storingandhandling 1

    Cleaning 2

    Sawing,routing,andlasercutting 2

    Tipsforcutting 3

    Drilling 5

    Shearing,punching,anddiecutting 5

    Bonding,fastening,andwelding 7

    Tipsforbonding 11

    Forming 12

    Tipsforthermoforming 15

    Decorating 16

    Summaryoffabricatingandforming 18

    Note: Conversion of metric/U.S. customary values may have been rounded off and therefore may not be exact.

  • Fabricating and forming sheet

    EastmanSpectarcopolyester14471,alsoknownasPETG,

    isaplasticresinspecificallydesignedforthicksheet

    applications.ItisproducedinpelletformbyEastman

    ChemicalCompany,andconvertedintosheetbyvarious

    commercialextruders.

    General health and safety precautionsSafetyAlwaysexercisegood,safeshoppracticeswhenfabricating

    orformingsheetofEastmanSpectarcopolyesterand

    otherplasticmaterials.Heatgeneratedduringsawing,

    machining,finishing,andthermoformingoperationscan

    burnunprotectedskin.Flyingparticlesandcontactwith

    chemicalsandvaporsarealsoareasofconcern.Besureto

    adherestrictlytoallinstructionsinMaterialSafetyData

    Sheets(MSDS)providedbyequipmentandmaterial

    suppliers.Inaddition,keeptoolssharpandingood

    workingorderforsafeoperationandhigh-qualitywork.

    VentilationItisalwaysgoodshoppracticetoworkinawell-ventilated

    area,particularlywhensolventbonding,cementing,orlaser

    cutting.Providelocalizedexhaustventingintheworkarea.

    Protective equipment Alwaysuseappropriatesafetyequipment(goggles,gloves,

    hearingprotection,etc.)whenhandlingplasticsheetand

    operatingshopequipment.

    Storing and handling Sheet stockHeavy-gaugeplasticsheetisgenerallyshippedincorrugated

    cases,onpallets,orascontinuousrolls.Storelargesheet

    flatwithmaskingintact.Sheetstoredonedgeinstorage

    racksshouldhaveasupported,slightlyangledbackboard

    (A-frame)topreventsheetfromwarping.Besurestorage

    areasareclean,dry,cool,andwell-ventilated.Whenpossible,

    rotateinventoriesonafirst-in/first-out(FIFO)basis.

    MaskingSheetofEastmanSpectarcopolyesterisprotectedwith

    amaskofpolyethylenefilm.Wheneverpossible,leavethe

    maskingintactduringfabrication.Useolderstockfirst.

    Also,avoidanyunsupportedoverhangofthesheetduring

    storage.

    Removeanymaskingadhesiveresidueonthesheetwith

    aclean,softclothdampenedwitha50:50mixtureof

    isopropylalcoholandwater.Ifthesheethasastaticcharge

    afterremovingthemasking,wipethesheetwithaclean

    clothslightlydampenedwithwatertohelpremovethe

    charge.

    Handling formed partsFormedpartswillcontinuetocoolaftertheyareremoved

    fromthemold.Topreventdeformation,itisimportantto

    providepropersupportduringcooling.Also,avoidany

    unsupportedoverhangoftheflatsheetorformedparts.

    Topreventdishing(becomingconcave),supportpartsalong

    theiredges,facedown,untilcompletelycooled.Donot

    nest-stackformedparts.

    General handling and storage recommendationsWeargloveswhenhandlinglargesheetstopreventcuts.

    Keepmaskinginplaceforaslongaspossible.

    Keeptabletopscleantoavoidscratchingthesheet.

    Storesheetsflat,asdelivered,topreventwarpage.If

    verticalstorageisnecessary,itisbesttostorethesheet

    andformedpartsataslightanglewithfullsupport

    underneath.

    Supportlarge,formedpanelsbytheiredges,facedown,

    whilecooling.

    Storematerialindoorsinadry,cool,well-ventilatedarea.

    UsetheFIFOmethodtorotateinventory.

    Donotuseaknifeorscrapertoremovemasking.

    Donotstoreplasticsheetnearradiators,steampipes,or

    indirectsunlight.

    1

  • CleaningDust and dirtRemovedustanddirtfromsheetofEastmanSpectar

    copolyesterwithasoftcottonclothandasolutionofmild

    soaporliquiddetergentinwater.A50:50solutionof

    isopropylalcoholandwateralsoworkswell.Remove

    greaseandresiduefromtapeorpapermaskingwith

    naphthafollowedbyawaterwash.Alwaysuseasoft,

    dampclothandblotdry.Rubbingwithadryclothcan

    scratchthematerialandcreateastaticcharge.Neveruse

    scrapersorsqueegeesonSpectarsheet.Seeadditional

    cleaninginstructionsonpage16.

    Do NotUse a squeegee.Use strong solvents.Rub with a dry cloth.

    Sawing, routing, and laser cuttingGeneral recommendationsIfpossible,leavetheoriginalmaskingonthesheetduring

    cuttingoperations.Inaddition,coverworkingsurfaceswith

    asoft,cleanclothtopreventscratching.

    Usesharp,cleanblades,holdingthesheetsecurelyinplace.

    Bringthebladetofullspeedbeforestartingthecutand

    usecompressedairtocoolthebladeandremovechips.

    Wearpropersafetyequipmentincludingsafetyglasses,

    gloves,andprotectiveclothingasrequiredbyapplicable

    regulations.

    Saw and cutter typesMostsawscommonlyusedforwoodormetalshould

    satisfactorilycutsheetofEastmanSpectarcopolyester.

    Theseincludecircularsaws,bandsaws,sabersaws,jigsaws,

    hacksaws,orhandsaws.However,circularsawsandband

    sawsusuallyproducesmoother,cleaner,fastercuts.

    Routingisalsoacommontechnique.

    Forthehighestqualitycut,useatriple-chipstylecarbide-

    tippedbladecommonlyusedforplastics.SeveralSpectar

    sheetscanbestackedandcuttogetherbutonlyifthe

    stackisheldsecurelytopreventmovementfromsheetto

    sheet.Otherwise,chippingandirregularcutsmayresult.

    Useaslowandconsistentfeedrate.

    Blade characteristics Circular saws

    Numberofteeth2to4teethper25mm(perinch).

    Bladethickness2.5mm(3#@in.)forsinglesheetsin

    thicknessesof1to10mm(0.040to0.375in.);3-mm

    (l-in.)bladeshouldbeusedforcuttingthickersheet.

    Bladetoothrakeangle05.

    Depthofcutforbestresults,allowthebladeto

    protrudethroughthepiecebynomorethan3mm

    (lin.).Thiswillminimizethechanceofcreatinga

    chippededge.

    Forcircularsaws,thefollowingbladespeedsare

    recommended.

    Blade diameter, mm (in.) Blade speed, rpm

    100(3.54)Trimmingsaw,usewoodcombinationblade

    10,000

    180(7d) 5,000

    200(8) 4,300

    250(10) 3,400

    300(12) 2,900

    350(14) 2,500

    Band saws

    Numberofteeth8to14teethper25mm(perinch)

    forgeneralcutting;18to24per25mm(perinch)fora

    smoother,cleaneredge.

    Bladewidthforintricatecutsandtighterturns,

    6to10mm(dtomin.)issuggested.Forstraightcuts,

    largerturns,12to25mm(ato1in.)issuggested.

    Bladespeedapproximately760mm(2,500ft)

    perminute.

    Saber saws and jigsaws

    Alwaysholdyourworksecurelyinplace.Thisisespecially

    importantwhenusingasabersaworjigsaw.Excessive

    vibrationcancausecrackingand/orpossibleinjury.

    Abladewith6to10teethper25mm(perinch)works

    wellwiththeorbitalactionsettingatzero.

    Ascroll-typebladewith12to20teethper25mm

    (perinch)canbeusedtoachieveagoodedgefinishon

    intricatecuts.

    2

  • Handsaws and hacksaws

    AlthoughnotcommonlyusedonsheetofEastman

    Spectarcopolyester,handsawsandhacksawscanwork

    satisfactorilyifusedcarefullyandwithlittlepressure.Use

    sharpbladesthatrangefrom6to18teethper25mm

    (perinch),dependingonthedesiredfinish.Asalways,

    securelysupportthesheettoavoidflexing.

    Routers

    Routingwithsharp,two-flute,carbide-tippedstraight

    cuttersproducesverysmoothedges.Twistedtwo-fluted

    cuttersworkexceptionallywell.Alsospiral-cutrouterbits

    havebeenfoundtoworksuccessfully,dependingonthe

    application.Itisespeciallyusefulfortrimmingedgesofflat

    orformedparts,orpartstoolargeorirregularinshapeto

    cutwithabandsaw.Portable,overarm,andsmalltable

    routersworkequallywell.

    Userouterspeedsof18,00032,000rpmtoproduce

    good,cleanedges.

    Feedthesheetintotherouterslowlytoavoidexcessive

    frictionalheating,shattering,orchipping.

    Useasuitablejigtosupportthesheetduringrouting.

    Usecompressedairtocoolthebitandtoaidinchip

    removal.

    Laser cutting

    EastmanSpectarcopolyestercanbelasercutusingthe

    sameequipmentasthatusedforcuttingacrylic.Typically

    lowerpowersettingsandslowercuttingratesarerequired

    whencuttingSpectarsheetvs.acrylicsheet.Itisalso

    recommendedthatacuttingtablewithgoodvacuum

    ventilationbeutilizedtoremovetheby-productscreated

    duringthecuttingprocess.ThisappliesforbothSpectar

    andacrylicsheet.

    Eastmaniscurrentlyworkingwithlaserequipmentto

    betterunderstandthelasercuttingsystemwhenworking

    withSpectarsheet.PleasecontactEastmantechnical

    serviceforfurtherupdates.

    Tips for cutting Eastmansrecommendationsarebasedonexperience

    workingwithsheetofEastmanSpectarcopolyester.They

    canbeusedasastartingpointorasguidelinesforcutting

    theseproducts.

    Usetoolsdesignedforplastic.

    Usesharpblades:Jigsawsshouldbeequippedwitha

    scroll-typebladefordetailworkandacoarse-toothed

    bladeforbetterchipremovalonheavierwork.Forcircular

    saws,acarbide-tipped,triple-chiptoothpatternis

    recommended.

    Holdsheetfirmlywhilecuttingtominimizevibration,

    especiallyforthinnergauges(

  • Operation Type of equipment Recommendations

    Trimming

    Routerbitsd-inchminimum,single-ordouble-flutedup-spiralbitsarerecommended,34flutedforlargerbits(i.e.,Onsrud#52-624).

    Routerblades4-Wingcarbidetip,slottingcutter(i.e.,WhitesidePart#6700B),>20Krpm,slow/medcutspeed

    Jigsaw Recommend10teeth/inchforsmoothestcut

    Bandsaw Recommendminimumof6teeth/inch

    Circularsaw(3.54-diameter)

    Carbide,triple-chiptoothcutrecommendedifcanfind,otherwiseuseawoodcombinationblade(i.e.,Makita),2mm-rake,>10Krpm.

    Circularsaw,7-diameter 60-toothcarbide-tippedblade,triple-chiptoothcutifpossible

    Rot