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DESK ORGANISER

MANUFACTURING METHOD ONE

V. Ryan 2005

 

MANUFACTURING A VACUUM FORMED BASE

   

This desk organiser is made from PVC (Poly Vinyl Chloride) tube. This material is supplied in a range of colours. It is quite soft and easy to cut, shape, machine and forms well when heated.

The example shown opposite can be manufactured in a number of ways. One technique is explained below.

   

The base / dish can be manufactured by vacuum forming. The manufacturing technique is described below.

A suitable mould / former is carefully manufactured. The edges of the top face are rounded so that the mould can be removed from the plastic easily after forming in the vacuum former. MDF is a suitable material for a former/mould.

The mould is placed in the vacuum former

   

Plastic sheet is placed above the mould and clamped securely.

   

The electric heater is turned on to warm the plastic sheet.

   

 

   

The plastic becomes flexible when heated

   

The air is pumped out of the area below the plastic and mould.

   

The hot plastic forms over the mould, taking on its shape.

When the plastic is removed and flipped over, the mould is still in place. It is then carefully removed by lightly tapping it, until it drops out. However, if the mould is badly made it may stick inside the plastic or damage the plastic as it is forced out.

   

The excess plastic is cut away using a band saw. The waste is placed in the recycling bin.

   
 
   

A profile cutter is used to smooth the edges. The cutter is fine and spins at a very fast rate removing a small amount of plastic.

   

The dish is now complete. It has smooth edges and all that is left is to manufacture the tubes and glue them into position.
   

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