CategoryMaterials & Sheet Quality
Prevent haze, bubbles, orange peel, and surface distortion in PETG by controlling heat exposure, sheet condition, temperature uniformity, and cooling.
- Symptom
- Burns & Discoloration, Surface Appearance
- Cause
- Heating & Temperature, Moisture & Material Condition
- Material
- PETG
CategoryMaterials & Sheet Quality
Stop PETG trim strings, melted edges, burrs, and reattachment by correcting cutter sharpness, speed, feed, chip removal, support, and sheet temperature.
- Symptom
- Surface Appearance
- Cause
- Machine Setup & Controls, Heating & Temperature
- Material
- PETG
CategoryProcess Control & Machine Diagnostics
Correct heater and mold temperature overshoot caused by aggressive tuning, sensor lag, output limits, startup conditions, or changing thermal load.
- Symptom
- Burns & Discoloration, Surface Appearance
- Cause
- Heating & Temperature, Machine Setup & Controls
- Material
- General / Multiple Materials
CategoryPre-Stretch & Plug Assist
Coordinate plug engagement and vacuum or pressure application to prevent uneven walls, webbing, chilling, tearing, and premature tool contact.
- Symptom
- Process Variation & Asymmetry
- Cause
- Pre-Stretch & Plug Assist, Vacuum & Venting
- Material
- General / Multiple Materials
CategoryPre-Stretch & Plug Assist
Identify off-center or tilted plug motion that causes one-sided thinning, contact marks, tearing, cavity variation, and uneven wall distribution.
- Symptom
- Thinning & Thickness Variation, Process Variation & Asymmetry
- Cause
- Pre-Stretch & Plug Assist, Machine Setup & Controls
- Material
- General / Multiple Materials
CategoryPre-Stretch & Plug Assist
Diagnose local freezing at plug contact that causes chill marks, stress whitening, tearing, and poor thickness distribution.
- Symptom
- Tearing, Cracking & Whitening, Surface Appearance
- Cause
- Pre-Stretch & Plug Assist, Heating & Temperature
- Material
- General / Multiple Materials
CategoryPre-Stretch & Plug Assist
Prevent visible plug witness marks by controlling sheet softness, plug temperature, finish, covering, contact pressure, alignment, and timing.
- Symptom
- Surface Appearance
- Cause
- Pre-Stretch & Plug Assist, Heating & Temperature
- Material
- General / Multiple Materials
CategoryPre-Stretch & Plug Assist
Correct sheet adhesion to a plug assist caused by excessive contact temperature, high friction, contamination, poor release, or prolonged dwell.
- Symptom
- Sticking & Release Damage
- Cause
- Pre-Stretch & Plug Assist, Contamination & Handling
- Material
- General / Multiple Materials
CategoryPre-Stretch & Plug Assist
Correct wall thickness shifted by plug shape, penetration, temperature, friction, clearance, motion, or an incorrect pre-stretch profile.
- Symptom
- Thinning & Thickness Variation
- Cause
- Pre-Stretch & Plug Assist, Mold Geometry & Material Distribution
- Material
- General / Multiple Materials
CategoryPre-Stretch & Plug Assist
Prevent sheet rupture caused by aggressive plug speed, sharp plug geometry, misalignment, low sheet temperature, poor pre-stretch, or excessive penetration.
- Symptom
- Tearing, Cracking & Whitening
- Cause
- Pre-Stretch & Plug Assist, Mold Geometry & Material Distribution
- Material
- General / Multiple Materials
CategoryVacuum, Pressure & Pneumatics
Find blocked silencers, small exhaust ports, kinked tubing, and trapped backpressure that slow valves, cylinders, clamps, plugs, or pressure release.
- Symptom
- Poor Detail & Incomplete Forming
- Cause
- Pressure & Airflow, Machine Setup & Controls
- Material
- General / Multiple Materials
CategoryMaterials & Sheet Quality
Prevent bubbles in thermoformed polycarbonate by following grade-specific drying, protected storage, controlled handling, and verified sheet temperature.
- Symptom
- Bubbles & Blisters
- Cause
- Moisture & Material Condition, Heating & Temperature
- Material
- Polycarbonate
CategoryMaterials & Sheet Quality
Reduce polycarbonate cracking caused by residual forming stress, sharp geometry, forced assembly, incompatible chemicals, machining, or poor drying.
- Symptom
- Tearing, Cracking & Whitening
- Cause
- Moisture & Material Condition, Cooling, Shrinkage & Release
- Material
- Polycarbonate
CategoryMaterials & Sheet Quality
Control HDPE and other polyethylene distortion by managing orientation, grade, wall distribution, mold temperature, cooling, geometry, and release timing.
- Symptom
- Warping & Dimensional Distortion
- Cause
- Cooling, Shrinkage & Release, Moisture & Material Condition
- Material
- Polyethylene
CategoryHeating & Sheet Temperature
Identify microbubbles, discoloration, odor, scorching, and strength loss caused by excessive thermal exposure during thermoforming.
- Symptom
- Burns & Discoloration
- Cause
- Heating & Temperature, Moisture & Material Condition
- Material
- General / Multiple Materials
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