Hey guys just wanted to give a place to share your ideas and opinions on the new Phlatboyz machine the PhlatFORMER
Here is the video and some pictures from the live PhlatLAB show where we build and show case prototype #1 of the PhlatFORMER

We have to say that we are super happy the way this tool turned out for a first prototype especially with all the new features added and tried for the first time. The next phase will be testing and experimenting with different materials and heat sources. We are sure to have another show with the final prototype demonstration and show and tell.
Thank you guys for keeping this and exciting and fun time for all!
Mark and Trish

PhlatFORMER specs so far:
* 18" L x 13-1/4" W x 7" H
* 10" x 10" forming area
* Lifting hinge frame for taller parts
* All hardware will be included for assembly


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Attached files

 

That is such as cool product, Mark! I've read much about doing Vacuum Forming, and have considered on many occasions building one. Now I don't have to bother - I'll just buy a kit from you guys!

Ray, I was able to see the video without any problems. It's a UStream embed and I'm using FireFox...

 

Thanks Mike I have a few tweaks here and there but its really going along good now.
I hope to have the rubber sealer section by this week end and we are getting snowed in so maybe we will have a testing show

Ray I added the video link under the video now, thank you for letting us know. I think its a setting in FireFox that gives people trouble with that. But the ink should work fine.
Mark

 

Thanks Travis,
This is a really good question and I will do my best to explain
This type of vacuum former is sort of a cross between a pressure former/ vacuum former
It utilizes the pressure from the above (the neoprene screen) and the vacuum from below.
I wanted to do it this way because in the test that I did on the normal vacuum only style machines, in order to get a fine detailed pull you would have to heat the plastic up too much so when it pulled it would leave the fine details but it would stretch the plastic so thin in order to pick up the details that the pulls came out very brittle and thin.
The other option was to heat the plastic up to the right temperature and then pull the vacuum and taking one hand from the screen (wearing gloves) you would have to quickly press the plastic into the part being molded to try and pick up the details. You could of coarse not get every area before the plastic hardened and it would leave glove prints on the plastic as well.
But the idea of creating this style machine was not really from the problems listed above but more because I on the normal vacuum style machines I would have so much wasted plastic because it need the out side edge of every sheet to create the seal to make the pull.
Beyond that I found myself running into problems of having different sizes of plastic sheets that I wanted to use but I would have to make a frame for each different size.
So I thought there must be a way to do this where we can use any size plastic we want without having to make frames and without have to over heat to pick up details.
As it turns out Blindflight (Al) here on the Phlatforum works in a place that makes custom wheelchair accessories for handicap clients and they have a professional vacuum forming machine there and this is how they are able to pull some of the thicker plastics as well.
As for heating the plastics you can use a frame if you like if you have several of the same size sheets or you can use just the sheet. Since the rubber sheet is taking the place of the air press from above its this sheet that makes the seal complete and allows for the vacuum to do the rest.
I Hope the helps to explain the idea behind the PhlatFORMER concept. Now we just need to run it through it paces and make sure it works as well as we hope
Here is the definition of pressure forming, where air pressure for us is replaced by the neoprene sheet.

Pressure forming - In addition to utilizing a vacuum underneath the sheet, air pressure (typically 50 psi, but up to 100 psi) is applied on the back side of the sheet to help force it onto the mold. This additional force allows the forming of thicker sheets and creating finer details, textures, undercuts, and sharp corners.

 

This is very cool!
I know what you were talking about in the vid about the shower liner rubber stuff. I agree with you thinking it would be too thick. I'm curious to what you will find for that rubber piece though. It would need to be pretty flexible and stretchy I would think.

 

Thank you guys for all the words of encouragement! This is our drive...

Travis and Shaun, To answer the questions on the material used. I did stop by an looked at the tool box liners while I was in Lowe's and I have some here at the house. I just don't think it will stretch enough for what we are trying to do.
I am getting a sample of the stuff they use on the industrial machines and I will try that out.
I am told by Al that it is a clear material, which is nice because you can see to line up the part as you go in to seal it
Julian, If this one goes well and there is a demand I don't see any reason why we could not make a larger version as well.
Dennis, I am not sure what the problem could be. I have four computers here and all of the videos show up fine. I think it must be that work computer locking flash out?
Larry, We are not stopping until all of us has the ability to own a state of the art miniature factory right in their garage. Capable of producing whatever a person can dream up, all a t prices we can afford

Thanks again guys, it means a lot to us.
Mark and Trish

 

Cool idea, if you want to design it I will cut a mold out and cast it in plaster and give it a go on the prototype machine maybe we could do it on a live show? Then I could mail you the cast and the pull
Mark

 

Thank you guys I hope that it works like its be planed
Erik here is what I was thinking of using http://www.target.com/s/186-9086908-699 ... r%5Fsingle


or something like it. I don't think you will need a diffuser to dissipate the heat because this is already 8" Would have to build a wire rack of sorts to hold the plastic above the heat and it will be nice to be able to flip it over and get both sides too
Mark

 

Thank you everyone for all of the positive feedback!! We're so excited!!

How about one of these to hold the plastic while it's warming over the hot plate? It opens and snaps closed. Attached files .jpg]

 

Hey Mark, have you guys ever thought of trying a large inner tube for the rubber part? Maybe the kind that you float around on at the lake? Pretty thick but also very flexible. Not clear but hey price is also an issue here and you could get lots of material from one tube.

-Buk

 

That's a good idea Buk! I will see what they have here at the lake. But I think your right it may be to thick especially the larger ones like they have here from truck tires.
I was at the hardware store yesterday and asked them about thin latex sheets and they said they have them, but when they went back to check they were out!
I do have some test samples coming in the mail from Blindflight so we will see how it goes with those.
It was supposed to be here today but I don't think the mail is going to make it today Attached files

 

Lol, you may be right. All of ours was in the form of rain, we are dealing with flooding now. I would have rather had the snow.

 

I wonder if when this melts we will have the flooding problem as well?
Mark