CategoryProcess Control & Machine Diagnostics
Correct false sag detection caused by dirty optics, sheet color, reflections, frame position, sensor alignment, threshold settings, and mechanical movement.
- Symptom
- Process Variation & Asymmetry
- Cause
- Heating & Temperature, Machine Setup & Controls
- Material
- General / Multiple Materials
CategorySurface Quality & Contamination
Trace scratches to sheet handling, masking, dust, mold contact, stacking, trimming, or release and prevent damage at the correct process stage.
- Symptom
- Surface Appearance
- Cause
- Contamination & Handling
- Material
- General / Multiple Materials
CategoryProcess Control & Machine Diagnostics
Correct plug, platen, clamp, and transfer position errors caused by homing faults, encoder drift, lost motion, limits, or mechanical slip.
- Symptom
- Process Variation & Asymmetry
- Cause
- Machine Setup & Controls, Mold Geometry & Material Distribution
- Material
- General / Multiple Materials
CategoryClamping, Sheet Loading & Tool Setup
Prevent nicks, saw cuts, cracks, crushed edges, and handling damage from propagating into clamp-zone tears or formed-part fractures.
- Symptom
- Tearing, Cracking & Whitening
- Cause
- Contamination & Handling, Moisture & Material Condition
- Material
- General / Multiple Materials
CategoryClamping, Sheet Loading & Tool Setup
Prevent off-center forming and uneven material supply by controlling cut-sheet size, squareness, loading stops, automation, clamp sequence, and detection.
- Symptom
- Process Variation & Asymmetry
- Cause
- Machine Setup & Controls, Moisture & Material Condition
- Material
- General / Multiple Materials
CategoryClamping, Sheet Loading & Tool Setup
Diagnose curl, twist, anisotropic shrinkage, and directional tearing caused by residual extrusion orientation or incorrect sheet loading direction.
- Symptom
- Warping & Dimensional Distortion
- Cause
- Moisture & Material Condition, Heating & Temperature
- Material
- General / Multiple Materials
CategoryMold Design & Material Distribution
Diagnose sheet pull-in at the clamp edge and correct insufficient grip, excessive forming load, hot edge zones, poor frame design, or damaged sheet.
- Symptom
- Process Variation & Asymmetry
- Cause
- Machine Setup & Controls, Heating & Temperature
- Material
- General / Multiple Materials
CategoryCooling, Shrinkage & Demolding
Understand shrinkage distortion in amorphous and semicrystalline sheet and control tool temperature, orientation, cooling, geometry, and release.
- Symptom
- Warping & Dimensional Distortion
- Cause
- Cooling, Shrinkage & Release, Moisture & Material Condition
- Material
- General / Multiple Materials
CategoryVacuum, Pressure & Pneumatics
Diagnose delayed or restricted vacuum-valve opening caused by actuator wear, low pilot pressure, contamination, undersized ports, or control lag.
- Symptom
- Poor Detail & Incomplete Forming
- Cause
- Vacuum & Venting, Machine Setup & Controls
- Material
- General / Multiple Materials
CategoryProcess Control & Machine Diagnostics
Identify solid-state relays that fail open, fail closed, leak current, overheat, or switch intermittently and destabilize heater-zone output.
- Symptom
- Poor Detail & Incomplete Forming, Process Variation & Asymmetry
- Cause
- Heating & Temperature, Machine Setup & Controls
- Material
- General / Multiple Materials
CategoryTrimming & Secondary Operations
Correct white trim edges caused by residual forming stress, excessive cutting deformation, blunt tools, poor support, or trimming at the wrong temperature.
- Symptom
- Tearing, Cracking & Whitening
- Cause
- Machine Setup & Controls, Moisture & Material Condition
- Material
- General / Multiple Materials
CategoryCooling, Shrinkage & Demolding
Prevent white marks created during part release by correcting hot demolding, undercuts, poor draft, high friction, uneven cooling, and eject force.
- Symptom
- Tearing, Cracking & Whitening, Sticking & Release Damage
- Cause
- Cooling, Shrinkage & Release, Mold Geometry & Material Distribution
- Material
- General / Multiple Materials
CategoryHeating & Sheet Temperature
Learn why white marks appear during forming, plug contact, trimming, or demolding and how to reduce local strain, chilling, and residual stress.
- Symptom
- Tearing, Cracking & Whitening
- Cause
- Heating & Temperature, Mold Geometry & Material Distribution
- Material
- General / Multiple Materials
CategoryProcess Control & Machine Diagnostics
Find transient voltage drop that reduces heater power, slows recovery, destabilizes controls, or appears only when ovens, pumps, compressors, and motion systems operate together.
- Symptom
- Process Variation & Asymmetry
- Cause
- Heating & Temperature, Machine Setup & Controls
- Material
- General / Multiple Materials
CategorySurface Quality & Contamination
Diagnose haze in clear thermoformed parts caused by moisture, overheating, underforming, crystallization, abrasion, contamination, or tool texture.
- Symptom
- Surface Appearance
- Cause
- Heating & Temperature, Moisture & Material Condition
- Material
- General / Multiple Materials
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