Deep Draw / Large Parts

Hampel incorporates capability to produce parts up to 70” deep. When the ratio of the area of the fully molded part is more than two times that of the area of the flat unmolded sheet, the part is defined as deep draw. For example, at a 2:1 ratio, a 1⁄4” starting gauge sheet will yield a finished nominal part thickness of 1/8”. Although Hampel produces many deep draw parts, the best example of this process is our ownCalf-Tel, which reflects an actual 3:1 draw ratio. In addition to Hampel’s deep draw expertise, we maintain the ability to produce large parts up to 7ft x 11ft in size.

January 2001 - Job Shop Technology Article

Twin Sheet

Twin sheet forming as explained in Thermoforming 101, provides hollow or structurally sound parts with many advantages over other processes such as blow molding or rotational molding. Twin sheet parts can be prototyped off temporary patterns prior to producing production tooling thus allowing a design to be tested with an actual part. It also allows the ability to encapsulate parts or components for attachments or insulating properties. Unlike other processes, twin sheet forming allows the ability to produce a part with different colors on each side as reflected most clearly on Hampel’s own portable restroom units.

Vacuum Forming

This is the basic process of evacuating the air between a heated sheet of plastic and the mold. Most molds are aluminum castings providing low tooling costs and design flexibility to produce common parts that are seen in use daily. Truck bedliners, belt shields and motorcycle fairings are just a few of many applications. Numerous materials are available such as ABS, HIPS and HMWPE to meet the requirements of almost about any application. In addition to these basic materials, additional engineered resins consisting of additives, fillers or multi-layer exist to meet even more stringent application requirements.

Patterns and Prototypes

A pattern is the first step in the tool construction phase after a design or model has been determined. The pattern can also be utilized to produce prototypes for design and material validation. This is the point at which modifications can be incorporated prior to producing a production tool. Most patterns are produced from a special pattern wood or ren-board type product enabling ease of change. Hampel provides the expertise to facilitate design changes via pro-e models or manually to ensure the outcome is a quality part design for cost effective manufacturing.