TRINSEO 2024 Avonite Flex Forming and Fabrication User Guide

AVONITE™ Flex
Forming and
Fabrication Guide

2024 Avonite Flex Forming and Fabrication

This fabrication guide has been prepared to assist in the proper methods for forming, fabricating, and handling AVONITE™ Flex sheet products.
AVONITE™ Flex products are warranted to be free from defects at time of manufacture. Any materials found defective will be replaced promptly.
Information or references to application, code compliance or specific standards are provided for convenience only. The accuracy or suitability of any recommendations in this guide must be verified by the user, Trinseo disclaims any legal responsibility.
WHO WE ARE
Since 1983, the AVONITE™ Flex brand has been a pioneer in solid surfacing. We have been known for our unbridled passion and spirited innovations.
We have been with many of you from the beginning.
For more than 30 years, we’ve celebrated the relationship between extraordinary product, design and craftsmanship. We are inspired by and committed to designers and fabricators with a passion for bringing forth original ideas and taking them beyond the ordinary.
HOW TO USE THIS GUIDE
We at Trinseo hope you will find the following Forming & Fabrication Guide to be a useful tool. It was created to help you discover unlimited design possibilities, which will lead to wonderful solutions for you and your customers. Although many applications are
covered in this guide, there will be new applications that may not be covered in detail. Our Forming & Fabrication Guide is designed to provide you with the fundamental knowledge of thermoforming and fabricating the AVONITE™ Flex material. These fundamentals can be adapted for new applications.
If you have specific questions or requests, our friendly and expert technical staff is eager to help.
Feel free to call your regional representative or contact us at +1 (800)428-6648.
Important updates such as Technical Bulletins published after the printing date of this manual are also available for download. Certified fabricators should periodically check for updates and add them to this guide. For additional copies of this guide or quick references for your clients, please visit www.aristechsurfaces.com/avoniteflex where the complete guide is available for download.

Introduction

1.1 AVONITE™ Flex Introduction
AVONITE™ Flex is an unequaled material developed to provide the perfect synergy between the functional excellence of specialty sheets with unparalleled surface characteristics, tactile feel, and subtlety of solid surface.
AVONITE™ Flex provides surface solutions for everything from bathtubs, thermoformed integral sinks, formed shower walls, and more, with no change to vacuum forming equipment. 1.2 Handling
Always carry AVONITE™ Flex sheet vertically when possible. Handle full-size sheet carefully to avoid breakage or injury. It is recommended that two people carry full-size sheet. Make sure to support the center of the sheet to eliminate excessive sag, which could
cause a crack or damage. Be careful when moving AVONITE™ Flex sheet so as not to strike it against anything that could damage the decorative surface or the edge.
1.3 Transport and Storage
No special precautions need to be taken for transport and storage. According to the transport regulations the materials described here are not categorized as dangerous goods, so no labeling is required. For storage we recommend a stiff firm base (pallets) which allow the sheets to be laid down flat. Vertical storage on the longitudinal edge is possible when leaned against a flat surface (any curvature should be avoided).
Caution: risk of breakage.

Fabrication and Finishing

2.1 Machining and Tooling
The usual rules of good machining practice applyto the machining of the AVONITE™ Flex material. Anexperienced machinist will have no difficulty handlingthe materials as its working properties are similar tothose of brass, copper, and fine woods.
The AVONITE™ Flex material can be easily machinedwith ordinary woodworking tools, such as routers, saws,planers, lathes, drills, and sanders. All blades and bitsshould be Carbide tipped.
2.2 Routing and Shaping
Woodworking shapers and overhead, or portable routers are used in edge finishing operations and for cutting flat thermoformed parts. For edging small parts, the table router is convenient. (See Figure 1.) A portable router is useful when the part is too large or awkward to bring to the machine.
These machines should have a minimum no-load spindle speed of 10,000 rpm. Higher speeds are desirable and should be used if they are available. Two or three flute cutters, smaller than 1.5” (38 mm) in diameter, running at high speeds, produce the smoothest cuts. At slower spindle speeds, the cutter should have more flutes, or may be larger in diameter to produce the necessary surface speeds. The cutter should be kept sharp and should have a back clearance of 10° and a positive rake angle up to 15°.

2.3 Drilling
When drilling the AVONITE™ Flex material, best results are obtained when using standard twist drills which have been modified as follows:

1. High speed steel drills should be selected, having slow spirals and wide polished flutes.
2. Drills should first be ground to a tip angle of 60° to 90°.
3. Modify the standard twist drill by dubbing-off the cutting edge to zero rake angle.
4. Grind the back-lip clearance angles to 12° – 15°.

The AVONITE™ Flex material may be drilled using any of the conventional tools: portable electric drills, flexible shafts, drill presses or lathes. In general, drills should rotate at high speed and feed should be slow but steady.
Use the highest available speed with a drill press, usually 5,000 rpm. An exception to this rule should be made when drilling large holes where the drill speed should be reduced to 1,000 rpm. The drill should always run true since wobble will affect the finish of the hole.
When drilling holes which penetrate a second surface, it is desirable to back up the surface with wood and slow the feed as the drill point breaks through. For accuracy and safety, the acrylic should be clamped during drilling.

2.4 Cutting
As a general rule, a power saw is the best method ocutting the AVONITE™ Flex material. It is sometimesadvantageous to cut thin material at an elevatedtemperature with rule and blanking dies. Cold punchingand/or shearing should not be used since these methodswill fracture the material.
The type of equipment selected should be based onthe work to be done. Circular saws are preferred forstraight cutting. Jig saws and saber saws are suggested for cutting small radii curves and thin materials. Bandsaws are suggested for large radii curves and for straighcuts in thick acrylic. Routers and wood working shapers can be used for trimming the edges of formed parts.
Tempered alloy steel saw blades are the least expensiveto buy, give reasonable service, and are discarded whenworn out. Carbide tipped blades are more expensive, givelonger service, and can be resharpened. The followingtable can be used as a guide in selecting the propercircular saw blade:

THICKNESS OF ACRYLIC SHEET Inches (mm)| BLADE THICKNESS Inches (mm}| TEETH PER INCH (cm)
---|---|---
080 – 100 (2.0 – 25)
100 – 187 (2.5 – 4.7)
187 – 472 (47 – 12.0)| W16 – 332 (9.6 – 2.4)
W32 – 118 (2.4 – 3.2)
M32 – 148 (2.4 – 3.2)| § -14 (3 – 6)
6 – 8 (2 – 3)
5 – 6 (2 – 3)

Circular Saws Should:

1.  Be run at 8,000-12,000 RPM.

2.  Be hollow ground to aid cooling.

3.  Be slotted to prevent heat warping the blade.

4.  Have teeth with a uniform rake angle of 0° – 10°.

5. Have a slight set to give clearance of .010” to .015”
   (0.254 mm to 0.381 mm) and

6. Have teeth of uniform height.

An 8” (20.3 cm) diameter blade is used for light work and a 12” (30.5 cm) blade for heavy work. A two horsepower motor is suggested for driving these blades.
Masking tape applied over the area to be cut will reduce the tendency to chip during cutting. Acetone, toluene, or methylene chloride can be used to clean blades. Tallow or bar soap applied to the blade, helps to prevent gum buildup on the blade when cutting  heet masked with adhesive backed paper. Traveling saws cutting at 10 to 25 feet (3 to 7.6 meters) per minute are recommended for making straight cuts longer than 3 feet (91 cm) and for cutting sheets when it would be undesirable to slide them across the saw table.

AVONITE™ Flex material, backed with fiberglass reinforced plastics, are best cut by diamond abrasive wheels. Carbide tipped blades will do a good job but require frequent resharpening. Small diameter disposable alloy steel blades on high speed air powered
saws are also effective, especially in portable situations.
Variable speed band saws, which can run at 5,000 feet (1524 m) per minute and have a 28” to 36” (71 to 91 cm) throat, are best suited for production work. Metal cutting blades are the best type for cutting the AVONITE™ Flex material. The following table can serve as a guide for selection of a blade:

MINIMUM RADIUS TO BE CUT inches (mm)| BLADE  WIDTH Inches (mm)| BLADE THICKNESS Inches (mm)| TEETH PER INCH (cm)
---|---|---|---
1/2 (12.7)
3/4 (19)
1-1/2 (38)
2-1/4 (57)
3 (76)
4-1/2 (114)
8 (203)
12 (305)
20 (508)| 316 (4.7)
1/4 (6.3)
3/8 (9.5)
1/2 (12.7)
5/8 (15.9)
3/4 (19)
1 (25.4)
1-1/4 (31.7)
1-1/2 (38.1)| 0.028 (.71)
0.028 (.71)
0.028 (.71)
0.032 (.81)
0.032 (.81)
0.032 (.81)
0.035 (.89)
0.035 (.89)
0.035 (.89)| 7 (3)
7 (3)
6 (3)
5 (2)
5 (2)
4 (15)
4 (1.5)
3 (1.5)
3 (1.5)

The blade speed should be approximately 4,500 RPM for AVONITE™ Flex sheet thicknesses from 0.125” to 0.375” (3.2 to 9.5 mm) thick. Fine teeth with no set will produce a smooth cut if fed slowly. Sheets should be fed continuously and with even pressure to prevent the blade from binding and breaking. The blade should enter and leave the work slowly to prevent chipping. Should a burr form on the cut edge due to overheating, it can be removed with a scraper or other straight edged tool.

2.5 Finishing
The original surface of the AVONITE™ Flex sheet is manufactured with a high gloss finish. This surface finish changes once the sheet has been heated and then thermoformed, bent, or stretched. The resulting finish that is achieved after forming will vary  depending on the depth of draw and the degree of bending. In general, a satin finish is achieved on the deck (or top portion) of the formed part. The surface of the inner walls and base of a part formed in a female mold will result in a matte finish. The AVONITE™ Flex sheet will show more matting (or dulling) of the surface as the sheet is stretched and its thickness is decreased.
However, a more consistent matte finish can be achieved with the Enhanced- Matte version of the AVONITE™ Flex sheet. This product option consists of a factory finished surface to the sheet resulting in a uniform, matte surface finish throughout the formed part. The surface finish will also remain uniform when comparing a flat sheet to a formed part.

2.6 Sanding
Similar to other solid surface products, AVONITE™ Flex material can be sanded to achieve different surface finishes. Using a 6” (152 mm) or 8” (203 mm) random orbital sander will reduce your sanding time by HALF over conventional vibrating sanders and will achieve a more uniform finish. Whenever possible, use a sander with a  vacuum attached (especially if the tops are polished) to minimize grinding dust back into the top.
The Enhanced-Matte finish can be achieved by sanding the top surface of the AVONITE™ Flex sheet prior to heating and forming. Best practices include sanding the flat sheet using a random orbital sander (as described above) with 320 grit (or 40 micron) paper and following the sanding process described below.

Sanding Process:

1. Move the sander in a back and forth direction.
2. Overlap each pass by 50%.
3. Sand at a slow and even pace, approximately 1 to 2 inches (25.4 to 50.8 mm) per second.
4. Sand the surface until the high gloss finish is not visible.
5. Keep micron paper clean from sanding dust.
   This is easily done by putting the sanding pad on a piece of carpet while running and hold it down for a few seconds (check paper frequently).

*Each sheet of micron paper will sand 10 sq. ft (about 1 sq. M) of Aristech Surfaces AVONITE™ Flex material. Matte Finish
Using 40 micron paper, place a Scotch-Brite® pad, (#7447 Red) under the sanding pad to even out the finish. The matte finish is easily maintained and is usually the most suitable for lighter colors.
Satin Finish
Sand with 40 micron paper, repeat sanding process with 30  micron paper. Place Scotch-Brite® pad (#7448  light  gray) under sanding pad. Sand with Scotch- Brite® #7448 and soapy water. Homeowners may maintain this finish using a white Scotch-rite®and Soft-Scrub®.
Polished Finished
After sanding with 40 micron paper, repeat the sanding process with 30 micron paper. Use a 3M Super Buff adapter to prevent the arbor of the polisher from damaging the acrylic surface.

Abrasive Grade Comparison

Micron Grade| Industrial U.S. Mesh| FEPA or P-Grade| Japanese J15 Grade| Emery
---|---|---|---|---
100u| #150| | |
80| 180| | |
60| 220| P240| #240|
| 240| | 280|
40| 280| | 320|
| 320| P360| 360|
| 360| P500| 400| 1/0
30| 400| | 500| 2/0
| 500| P1000| 600| 3/0
15| 600| | 1000|
| 800| | 1200|
12| | P1200| |
9| 1200| | 2000| 4/0
5| | | 2500|
3| | | 4000|
2| | | 6000|
1| | | 8000|
0.3| | | |

2.7 Bonding and Seaming
Strong joints and seams can be obtained in bonding actions of AVONITE™ Flex sheet together, and with other materials, by giving careful attention to preparation of the mating surfaces, proper choice of adhesives/cements and following correct bonding techniques.
The surface of the AVONITE™ Flex material is also capable of  bonding to with FRP rigidizing systems.
Surface preparation of the AVONITE™ Flex material prior to spray application of FRP resins is similar to that of AVONITE™ Flex sheet.
Prevention of Internal Stresses
AVONITE™ Flex sheets need to be acclimated to ambient room temperatures prior processing. The AVONITE™ Flex sheet is not sensitive to humidity and moisture. Heat generated by machining operations, and/or thermoforming at reduced temperatures, will
often induce internal stresses which make the material susceptible to crazing after contact with solvents and certain adhesives/cements. Such stresses can be avoided by the proper choice of thermoforming or machining conditions or can be relieved by heat treating. Refer to the Annealing Section in Technical Bulletin 135 for proper heat treating conditions.
Joint Preparation
Surfaces to be jointed should be clean and fit together with uniform contact throughout the joint. In order to obtain close fitting edges, which is especially important, it may be desirable to accurately machine the mating surfaces.
Edge buildups such as stacked edges and exposed layered edges should not be used with Avonite Flex.
Prior to applying the joint adhesive, using a 100 grit sandpaper on hardwood block, lightly score the edges/ surfaces to be seamed together. This step aids in the adhesion between the two surfaces. Make one or two passes only. Be careful not to sand the top edge
of the sheet, or the outer edges of the formed part. After the dry fit is complete, clean edges/surfaces with isopropyl alcohol.
Joining
AVONITE™ Adhesive
Our adhesive is a pre-tinted two-part adhesive and cures in approximately 40 minutes and is available in 250 ml cartridges. The adhesive is available in several colors and clear for excellent color matches. It is specially formulated to offer superior bond strength for all AVONITE™ products.
Cartridges Each cartridge contains 250 ml (10 oz.) of adhesive andwill adhere 35 to 45 feet (12.1 M) of 1/2” (12.7 mm) seam.The adhesive flows through a static mixer tube and isready for use.
Two mixer tubes are included with each cartridge.To assure positive flow of activator, dispense a smallquantity of adhesive before installing mixer tube.50 ml sizes are also available.

FABRICATION TIP
From time to time the bead of adhesive dispensed with the AVONITE™ Solid Surface Adhesive cartridge will not contain the prescribed amount of hardener. This may arise for a variety of reasons, but the end result is that small sections of the seam may not set up as rapidly as others. There are techniques that will reduce the variation in setup time. Once the bead of adhesive has been dispensed, a popsicle stick applicator may be used to spread the adhesive over the bonding surface. This serves to blend the adhesive more uniformly with the hardener and prevents variation in the curing time of the adhesive. Another helpful technique used frequently is to dispense two thin beads as opposed to one thick bead. This method overlaps any possible gap in the hardener and prevents uneven hardening. When a small amount is needed there is no reason to waste a mixing tube. Simply remove the end plug and squeeze the adhesive into a paper cup and stir for one minute.

Other Types of Adhesives
AVONITE™ Flex material can also be joined together with the monomer-polymer solvent type or the monomerpolymer-catalyst type of adhesives.
Monomer-Polymer-Solvent Type Cements
These types of cements usually consist of methyl methacrylate monomer, methyl methacrylate polymer and assorted solvents. M-P-S type cements available are Weld-On 16 and Weld-On 1802. M-P-S cements do not allow rapid assemblies. Usually 15 to 30 minutes after cement is applied, part can be handled very carefully.High to medium strength joints are obtained which have good to fair weathering resistance.
Monomer-Polymer-Catalyst Type Cements
These type cements consist of methyl methacrylate monomer, Methyl Methacrylate Polymer (Part A) and a catalyst (Part B). M-P-C cements available are Weld-On 10, Weld-On 28, and Weld-On 40. These type cements yield excellent bond strengths, and weathering resistance. Assembly times are slow.

2.8 Annealing
When plastics parts are molded, fabricated, or formed in any fashion these processes inherently induce stress into the part. Just like glass, ceramic and metals, this stress can be relieved by a process called annealing. In annealing we heat the part heating to near the glass transition temperature, maintaining this temperature for a set period of time, and then slowly cooling it to room temperature.
A part undergoing annealing should be completely supported. If it is simply a sheet it can be laid flat in the oven. More complicated parts can require jigs to ensure that the part is not distorted during the annealing process.
For AVONITE™ Flex, the typical temperature that it is heated to is 80°C and then cooled slowly. Generally, you heat the sheet one hour for each millimeter of thickness.
It is critical that the sheet be cooled at a controlled rate.
If you took the part out of the oven after it achieved 80 °C and cooled it under running water, you would build more stress into it rather than relieve it. Specially configured annealing ovens can program the annealing schedule. Most ovens will require that you  reset the temperature at intervals. The part does not have to be cooled all the way to room temperature before removing it from the oven. It can be removed once the temperature goes below 60 °C.
If the part has been cemented/glued it must be allowed to cure at least five hours before annealing. Rapid solvent evaporation can cause bubble formation.

Thickness| Heating Time(hours)| Cooling Time (hours)| Heating Rate (degrees Celsius per hour)
---|---|---|---
2.0| 2| 2| 15
2.5| 2.5| 2| 15
3.0| 3| 2| IS
3.2| 3.2| 2| 15
4.5| 5.| 2| 15
6.0| 6| 2| 15
9.5| 9.5| 2.5| 12
12| 12| 3.5| 11

 Thermoforming

These Thermoforming Parameters are basic guidelines for fabricators to thermoform AVONITE™ Flex material.
The parameters listed below are recommendations, which  are a direct result of actual forming of AVONITE™ Flex material. This testing was conducted by the AVONITE™ Flex Technical Service Department, but  values are approximate. We suggest re-testing
for varying conditions.
Material Preparation
When preparing material to be formed, it is recommended that material be cut to size. Then, remove all chips or gouges on the edge of the material. Any chip or gouge left on an edge may cause the material to tear during forming. Thermoforming temperatures given here are approximate and represent a starting point to establish the conditions you need for your project. If material is too cool or too hot it may crack or tear while bending.
Oven Options
Below are thermoforming guidelines for conventional and platen style ovens. Every oven is unique and calibrations may be necessary. Be sure the oven used is large enough for the entire piece to be formed. Mold Design
Thermoforming can be done on a male or female mold, depending on the geometry of the part being formed. The mold needs the edges designed to seal when the clamp frame engages with the mold. Molds can be made from a variety of materials and can be heated if made from aluminum. Vacuum should be supplied in sufficient quantity to achieve molding in 10 to 12 seconds. Undercuts cannot be done in thermoforming directly. They must be accommodated with inserts.

Fabrication: Finishing/Seaming
Finishing formed sheet stock is no different from standard finishing. However, it is important that any seaming/joining be done after forming. The heat to which the material is subjected will weaken the seamed areas of the pieces, which may result in seam failures.

3.1Thermoforming Temperatures and Cycles

The following curves (Figures 15 & 16) were derived from tests performed at Aristech Surfaces. Due to the large variety of heating equipment available, heating times may vary. The following heating cycles should be used as a starting point only in obtaining optimum forming temperature times and cycles. The temperature and cycle times depend upon the thickness of the AVONITE™ Flex sheet as well as the type of heating and forming equipment used.
Surface temperatures should not exceed 380 °F (194°C).
It  is  common practice, especially in high production operations, to allow surface temperatures to exceed 380 °F (194 °C). Higher temperatures can be tolerated up to 30 seconds depending on sheet thickness in most cases. But due to blistering potential, it  is not recommended to exceed 380 °F (194 °C).
Figure 16 outlines the heating cycles when using electric infra-red radiant heaters on one or two sides. Again, heating times can vary depending on the type of heating equipment used, percentage times, distance between sheet and heaters, and heat loss factors. Several other methods can be used to determine if a sheet has been sufficiently heated. The most common is the ripple method by which the operator shakes the heated sheet with a non-combustible object (See note). When the sheet ripples uniformly across the surface, it is ready for forming. Another commonly used technique is the “sag method”. By trial and error, the amount of sag in a hot sheet can be correlated with the optimum time to be thermoformed.
The best procedure for determining when the sheet is ready for forming is to accurately control the temperature using heat sensors and/or temperature indicating stickers. The actual cycle, temperature settings and techniques most suitable for a particular forming job are best determined on one’s own equipment.
Note: Care must be taken to make sure the operator does not endanger him/herself due to exposure to electricity, hot oven components, or hot sheet.
When measuring the de-mold temperature, you should be looking at the areas where the material remains thickest. This would be the deck areas of tubs or shower bases.
If  you have sticking problems with your molds you should find that use of talc or baby powder in the areas of sticking will most often help. The sticking can occur around the corners of the deck area, or near the drain end of the baths. That is when you may need the assistance of “air eject” to help relieve the vacuum effect of the part fitting tightly in the mold.
Should you encounter any problems with handling or processing of this new and exciting material, please don’t hesitate to contact the Aristech Technical Service department for assistance and advice.

3.3 Heating Equipment
Forced Air Circulating Ovens
Forced air circulating ovens generally provide uniform heating at a constant temperature with the least danger of overheating the AVONITE™ Flex sheet.
Electric fans should be used to circulate the hot air across the sheeting at velocities of approximately 150 ft / minute (46 m / minute).
Suitable baffles should be used to distribute the heat evenly throughout the oven. Heating may be done with gas or electricity. Gas ovens require heat exchangers to prevent the accumulation of soot from the flue gas.
Electric ovens can be heated with a series of 1000watt strip heating elements. An oven with a capacity of 360 ft³ (10 m³ ), for example, will require approximately 25,000 watts of input.
About one-half of this input is required to overcome heating losses through the insulation, leaks, and door usage. An oven insulation at least two inches thick is suggested. Oven doors should be narrow to minimize heat loss, but at least one door should be large enough to permit reheating of formed parts which may require reforming. The oven should have automatic controls so that any desired temperature in the range of 250 to 450 °F (121 to 232 °C) can be closely maintained. In addition, temperature recording devices are desirable, but not essential. Uniform heating is best provided when the sheet is hung vertically.
This can be accomplished by hanging the sheets on overhead racks designed to roll along a monorail mounted in the oven roof or in a portable unit. Precautions should be taken so that the sheet cannot fold or come in contact with another. A series of spring clips or a spring channel can be used for securely grasping the sheet along its entire length.

Infra-Red Heating
Infra-red radiation can heat AVONITE™ Flex sheetthree to ten times faster than forced-air heating. Thistype of heating is often used with automatic formingmachines where a minimum cycle time is important.Temperature control, however, is much more criticaland uniform heating is more difficult to obtain by thismethod. AVONITE™ Flex absorbs most of the infra-redenergy on the exposed surface, which can rapidly attaintemperatures of over 360 °F (182 °C). The center of the sheet is heated by a slower conduction of heat from thehot surface. This usually causes temperature gradientsacross the thickness. The gradient is more severe withinfra-red heating from one side only. Infra-red radiantheat is usually supplied with reflector backed tubularmetal elements, resistance wire coils or a bank of infrared lamps.
More uniform heat distribution can sometimes beaccomplished by mounting a fine wire-mesh screenbetween the sheet and the heat source. A temperature Controlled technology, such as a solid state PLC orpercentage timer on older apparatus should alwaysbe used for consistent results. Top infra-red heatersshould be approximately 12” (30 cm) from the sheet.Bottom heaters can be 18 to 20” (45 to 50 cm) away.

Types of Infra-Red Heating
A. Gas: Can be open flame (less common) or gas catalytic. Economical to run but poor control of the heat, impossible to control the heat profile.
B. Calrod: Electrical resistance elements such as the type used in domestic ovens. It is a nichrome wire surrounded by a silicon or mica insulator.
C. Nichrome Wire: An exposed nichrome wire without insulation usually set into channels in a ceramic or other insulative panel.
D. Ceramic Heating Elements: A nichrome wire embedded in an insulator and then sheathed in a ceramic tube.
E. Infrared Panel Heaters: Tungsten wire elements mounted in channels within an insulator panel.
F. Quartz Heating Element: The most common type of heating. You can better control the heat profile either by screening off sections or if the system has it, automated control of each heating zone. They use a tungsten wire element encased in a quartz tube.
G. Halogen: Like the quartz heating element, this heat source is a tungsten wire encased in a quartz tube, but the tube is sealed and filled with an inert halogen gas preventing oxidation of the element. This allows the element to go to much higher temperatures without burning out. The very best control of heat profile and heat flow. Halogen not as common because these systems are comparatively more expensive.

3.4 Three-Dimensional Forming
Techniques for three-dimensional forming of plastic generally require vacuum, air pressure, mechanical assists, or combinations of all three to manipulate the heated sheet into the desired shape. The basic forming techniques used for AVONITE™ Flex sheet are illustrated in the following drawings and described below.

1. Vacuum Forming A. Heated sheet in clamp frame.
   B. Mold is mechanically positioned to heated sheet, forming a seal. Vacuum is then applied to form part.

2. Orape/Vacuum Forming A. Heated sheet in clamp frame.
   B. The mold is forced mto the sheet to a depth that forms a seal around the penphery. Vacuum is then apphed to form the part.

3. Vacuum/Snap-Back Forming A. Heated sheet in clamp frame.
   B. Position vacuum chamber to heated sheet fo form seal. Appfy vacuum to form bubble to predefermimed height.
   C. Insert mold into heated/prestretched sheet to form seal. An control relieves vacuum in preform vacuum chamber.
   Apply vacuum to mold fo form part.

4. Prassure Bubble/Snap-Back Forming A. Heated sheet in clamping frame.
   B. Position pressure chamber into heated sheet to form seal. Apply pressure fo prestretched sheet to controlled height.
   C. insert mold into prestretched bubble at a controlled rate. Insert to depth required to form a seal.

5. Plug Assist— Vacuum Forming A. Heated sheet in clamping frame.
   B. Position mold mto heated sheet to form seal. Insert heated plug at controlled rate to the depth requried for preforming.
   C. Apply vacuum to form part.

6. Pressure Bubble/Plug Assist/Vacuum Farming fey (D) A. Heated sheet in clamping frame.
   B. Position mold into heated sheet to form pressure seal. Apply pressure to prestretch sheet to controlled height.
   C. Insert heated plug into bubble at a controlled rate to the depth required for preforming.
   D. Apply vacuum to form part.

3.5 Molds
Wood
Wooden molds are easily fabricated, inexpensive and can be altered readily. Wood molds are ideal for short production runs where mold markoff is not important and for prototyping.
Epoxy
Epoxy molds yield the least amount of mold mark off of any of the mold materials used. Epoxy molds can be used for medium production runs and have good durability provided they are properly fabricated.
Aluminum
Aluminum molds are used in high production operations.
Aluminum moIds will last indefinitely with little maintenance required.

Move heater farther away use screening It localized.
Poor definition of detail.
Incomplete forming| Sheet too cold.
Low vacuum.
Sheet too thick.
Low air pressure.| Increase heat input to sheet.
Check for leaks in vacuum system. increase number and/or size of vacuum holes. Add
vacuum capacity
Use thinner caliper sheet.
Increase volume and/or pressure.
Excessive thinning at bottom of
draw or comers| Poor technique.
Sneet 100 thin.
Drawdown too fast.| Change forming cycle to include billowing or plug assist. Use screening to control temperature profile.
Use thicker sheet.
Decrease rate of drawdown.
Extreme wall thickness variations.| Uneven sheet neating.
Mold too cold.
Sheet Slipping.
Stray air currents.| Check temperature profile.
Change heaters to provide hagher uniform mold surface temperature. Check cooling System for scale of plugs.
Adjust clamping frame to provide uniform
pressures.
Provide protection to elimmate drafts.
Excesswe Sag| sheet too hot.| Reduce time or temperature.
Pits or pimples.| Vacuum holes too large.
Vacuum rate too high.
Dirt on mold or sheet.| Use smaller holes.
Decrease vacuum rate or level.
Clean mold and/or sheet.
Part sticking to mold.| Rough mold surface.
Undercuts too deep.
Not enougn draft| Potish moid.
Reduce undercuts.
Change to split mold.increase draft of mold.
Mark-off| Dirt on sheet
Dirt on mold.
Dirt m atmosphere.
Sneel too nat.| Clean sheet.
Clean mold
Clean vacuum forming area. Isolate area if necessary and supply filtered air.
Reduce heat and heat more siowty.
Distortion in finished part.| Part removed too hot
Uneven heating.| Increase cooling time before removing part.
Check cooling system.
Check temperature profile.
Correct mold design — stiffen to eliminate.

Repair and Renew

These two repair methods are done by hand and will eliminate most scratches and mars to the finish. Wet sanding achieves the most favorable results; however, lighter colors usually do not require that. When using multiple grits to achieve a final finish, it is very important to thoroughly clean and wipe the area between each grit.
4.1 Repair Instructions for Light Colors
Lighter colors such as Pure Alabaster 8701, AlabasterWave 8705 and European White 8704 can be repairedwith the instructions below
Care And Maintenance
Each customer must receive AVONITE™ Flex Care & Maintenance information to ensure they understand the proper care and maintenance for the AVONITE™ Flex installation and to register for the 15-Year Limited Warranty, or the new Installed Warranty as appropriate. The AVONITE™ Flex Care & Maintenance information, as well as all warranty information is available online at www.aristechsurfaces.com
Cleaning
Soap and water will clean most stains. For more stubborn stains use a green Scotch-Brite® pad and an abrasive cleanser.
Scratches
To remove scratches, start sanding with 320 grit paper and then clean with an abrasive cleanser and a green Scotch-Brite® pad. Remember to periodically go over the entire matte surface with a dry, green Scotch-Brite® pad to return the original finish.

4.2 Repair Instructions for Dark Colors
Darker Colors such as Pure Ebony 8702 can be repaired with the instructions below.

1. With a random orbital sander, sand with 60 micron (220 grit) paper, micron paper overlapping each pass by 50%. Covering 4 passes.
2. Repeat sanding process with 30 micron (380 grit) paper, overlapping each pass by 50%. Covering 4 passes.
3. Place a Scotch-Brite (#7448 light gray) under the sanding pad. Sand with Scotch-Brite and soapy water, overlapping each pass by 50%. Covering 4 passes.
4. Final Finish

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As a contribution toward the protection of our environment, Trinseo’s printed literature is produced in small quantities and on paper containing recovered/ post-consumer fiber and using 100 percent soy-based ink whenever possible.
Product Stewardship
Trinseo and its affiliated companies have a fundamental concern for all who make, distribute, and use their products and for the environment in which we live. This concern is the basis for our Product Stewardship philosophy by which we assess the safety, health, and environmental information on our products so that appropriate steps may be taken to protect employee and public health and our environment. The success of our product stewardship program rests with each and every individual involved with Trinseo products – from the initial concept and research, to manufacture, use, sale, disposal, and recycle of each product.
Customer Notice
Customers are responsible for reviewing their manufacturing processes and their applications of Trinseo products from the standpoint of human health and environmental quality to ensure that Trinseo products are not used in ways for which they are not suitable. Trinseo personnel are available to answer questions and to provide reasonable technical support. Trinseo product literature, including safety data sheets, should be consulted prior to the use of Trinseo products. Current safety data sheets are available from Trinseo. No freedom from infringement of any patent owned by Trinseo or others is to be inferred. Because use conditions and applicable laws may differ from one location to another and may change with time, the customer is responsible for determining whether products and the information in this document are appropriate for the customer’s use and for ensuring that the customer’s workplace and disposal practices are in compliance with applicable legal requirements. Although the information herein is provided in good faith and was believed to be accurate when prepared, Trinseo assumes no obligation or liability for the information in this document.
NOTICE REGARDING MEDICAL APPLICATION RESTRICTIONS TRINSEO REQUESTS THAT CUSTOMERS REFER TO TRINSEO’S MEDICAL APPLICATION POLICY www.trinseo.com BEFORE CONSIDERING THE USE OF TRINSEO PRODUCTS IN MEDICAL APPLICATIONS. THE RESTRICTIONS AND DISCLAIMERS SET FORTH IN THAT POLICY ARE INCORPORATED BY REFERENCE.
For more information on products, innovations, expertise, and other services available from Trinseo, visit www.trinseo.com, or in the U.S. contact us at +1-855-TRINSEO (+1-855-874-6736).
DISCLAIMER
TRINSEO MAKES NO WARRANTIES, EITHER EXPRESS OR IMPLIED, IN THIS DOCUMENT; ALL IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE (INCLUDING MEDICAL APPLICATIONS) ARE EXPRESSLY EXCLUDED. SINCE THE CONDITIONS AND METHODS OF USE OF THE INFORMATION AND PRODUCTS REFERRED TO ARE BEYOND TRINSEO’S KNOWLEDGE AND CONTROL, TRINSEO DISCLAIMS ANY AND ALL LIABILITY FOR LOSSES OR DAMAGES THAT MAY RESULT FROM RELIANCE ON THE

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Trinseo (2024) All rights reserved.
™Trademark of Trinseo PLC or its affiliates ™Responsible Care is a service mark of the American Chemistry Council.

INFORMATION OR USE OF THE PRODUCTS DESCRIBED HEREIN. TRINSEO MAKES NO WARRANTIES, EXPRESS OR IMPLIED, THAT THE USE OF ANY TRINSEO PRODUCT WILL BE FREE FROM ANY INFRINGEMENT CLAIMS.
GENERAL NOTICE
Any photographs of end-use applications in this document represent potential end-use applications but do not necessarily represent current commercial applications, nor do they represent an endorsement by Trinseo of the actual products. Further, these photographs are for illustration purposes only and do not reflect either an endorsement or sponsorship of any other manufacturer for a specific potential end-use product or application, or for Trinseo, or for specific products manufactured by Trinseo.If products are described as “experimental” or “developmental”: (1) product specifications may not be fully determined; (2) analysis of hazards and caution in handling and use are required; (3) there is greater potential for Trinseo to change specifications and/or discontinue production, and (4) although Trinseo may from time to time provide samples of such products, Trinseo is not obligated to supply or otherwise commercialize such products for any use or application whatsoever.
For additional information not covered by the content of this document or to ensure you have the latest version of this document available, please refer to our website at www.trinseo.com/Contact-Us.
Questions pertaining to any procedure detailed herein should be addressed to the AVONITE™ Technical Services Department.
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References

• Aristech Surfaces | Now Part of Trinseo
• Trinseo Homepage
• Aristech Surfaces | Now Part of Trinseo
• Trinseo Homepage

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