SYNOPSIS-October 21, 2004-Jobwerx News-Vacuum formed ultra-thin and thick fluoropolymer films offer excellent corrosion and heat resistance.

Films that are made from polyethylene terephthalate (PET polyester), nylon, polycarbonate (PC), polyimide (PI), fluoropolymers, and exotic materials such as liquid-crystal polymers (LCP), polyetheretherketones (PEEK), polysulfones (PS), and polyether imides (PEI), lend themselves to meltprocessing techniques such as vacuum forming. They can also be used when coatings can't be applied due to chemical incompatibility with the substrate or environmental constraints, such as extreme low temperatures.

Advances in extrusion of ultra-thin films for vacuumformed parts are replacing thicker injection molded components. Better economics and poor quality also spur designers to go with thermoformed thin-film parts. Specially formulated versions of PI can be vacuum formed.

Fluoropolymer films are replacing glass, stainless, solid PTFE, and injection-molded parts in custom lab ware, reaction vessels for pharmaceutical research, and in food processing.

According to Welch Fluorocarbon in Dover, N.H., which thermoforms ultra-thin (less than 0.001-in) films into battery sleeves, vapor and corrosion barriers, pump liners, and other intricate parts for medical, aerospace, and other uses, if you can melt it, you can form it.

Cost-effective coextruded PEEK/PEI films are also emerging.

ULTEM, a new resin blend from GE Advanced Materials, a thermoformable, lightweight composite sheet, exhibits excellent flame, smoke, toxicity, and heat-release performance in large semi-structural panels for aircraft, trains, and other transportation segments. The product can be thermoformed, pressure formed, twin-sheet formed, or used in flat or cold-formed applications.

Ajedium Film Group LLC, Newark, Del., is working on films of less than 1 mil in PEEK, high-temperature nylon, and nylon/polyimide blends, which have not previously been available.

Many variables come into play when comparing thin films to coatings too. The up-front time for tooling, for example, is longer for vacuum forming. But once in place, thin-film parts provide a dramatic improvement over coatings. For example, strip and recoat times can run into days or weeks. On the other hand, conformal thin films and thermoformed liners can be replaced in the field in a matter of minutes. And depending on the type and complexity of the coated parts, a thermoformed alternative is usually less expensive.


Haven't found what you're looking for? Try Searching the Web above: For identifying the right resources and picking the correct films locate some of the following suppliers and processors of ultra-thin fluoropolymer films; Eagle Picher Technologies, DuPont Teflon Films, Honeywell Specialty Films, Ajedium Film Group, GE Advanced Materials, Welch Fluorocarbon.

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