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products/poly-mech/resources/material/hdpe/assets/conclusion.md

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+
+
+# Sheetpress Experiments - Cassandra - 650 - EDC - RC1 - Conclusion
+
+---
+
+## 10 mm
+
+A one-stage process suitable for up to 10 mm thickness, though prone to warping effects.
+
+### Conclusions
+
+- Minor flatness errors were observed, typically 0.5-1 mm.
+- Warping and material shrinking occurred, especially near corners.
+
+### Recommendations
+
+- Reheat at 140°C and press again to minimize shrinkage and warping.
+- For a better finish, repeat the press with a harder surface.
+
+
+---
+
+## 20 mm
+
+A two-stage method offering better control at greater thickness.
+
+### Conclusions
+
+- The inclusion of intermediate dies reduced warping and improved overall flatness.
+
+### Recommendations
+
+- Incremental heating and controlled die insertion are recommended.
+- Use presses with adequate pressure (20 tons minimum) for thicker sheets.
+
+---
+
+## 30 mm
+
+A two-stage method offering better control at greater thickness.
+
+### Conclusions
+
+- The inclusion of intermediate dies reduced warping and improved overall flatness.
+
+### Recommendations
+
+- Incremental heating and controlled die insertion are recommended.
+- Use presses with adequate pressure (20 tons minimum) for thicker sheets.
+
+---
+
+## 40 mm
+
+A three-stage process for 40 mm sheets with significant handling challenges.
+
+### Conclusions
+
+- Height differences were observed, particularly on the die-engaged side (up to 5 mm).
+- Air pockets and corner warping were frequent issues.
+
+### Recommendations
+
+- Implement intermediate reheating steps.
+- Introduce controlled cooling phases to mitigate height inconsistencies.

products/poly-mech/resources/material/hdpe/assets/extruded-130x130/readme.md

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+## Settings
+
+- **Mould Size**: 43 x 35cm x 2cm
+- **Mould height**: 40mm
+- **Mould sheets**: 1x sanded stainless | 1x polished stainless
+- **Mould release**: none
+
+- **Temp - UP**: 170
+- **Temp - DOWN**: 170
+- **Heat**: Cold Start
+
+- **Duration-Melt**: 95 min
+- **Duration-Pre-Cool**: 20 min (heater off)
+- **Duration-Cooling-Final**: 8h
+
+- **Preparation**: 2x layers: 7cm, another 3cm after compressing
+- **Excess**: none
+- **Method**: Mould frame, 2 passes
+
+- **Die Material**: sanded stainless
+- **Die Penetration**: 10mm
+
+- **Thickness Error**: 1mm per 50cm
+- **Flatness Error**: 1mm per 50cm
+- **Final sheet thickness**: 30.0 mm
+- **Contraction / Shrinkage**: 10mm per 50cm
+- **Surface Quality**: good
+
+## Probing / Flatness Report (on CNC, straightened)
+

products/poly-mech/resources/material/hdpe/assets/summary.md

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+
+
+# Sheetpress Experiments - Cassandra - 650 - EDC - RC1
+
+---
+
+## 10 mm
+
+A one-stage process, suitable for up to 10 mm thickness, requires careful setting and timing to avoid warping effects.
+
+### Description
+
+One-stage process for plastic sheet pressing.
+
+### Settings
+
+- Temperature: **155-160°C**
+- Cool-down temperature: **130°C**
+- Duration: **1 hour** for mold closing, **30 minutes** for cool-down
+
+### Requirements
+
+1. Place a stainless sheet inside the mold.
+2. Fill with plastic, carefully pressing.
+3. Avoid contact between the mounting edge and the mold.
+4. Wait **10 minutes** before full pressing.
+5. Wait **1 hour** for full mold closure.
+6. Cool to **130°C** and wait **30 minutes**.
+7. Remove the mold and access the formed sheet.
+8. For shiny/flat finish, press again with a harder surface.
+
+### Results
+
+- Small flatness errors (0.5-1 mm) based on press quality and plastic characteristics.
+
+### Problems
+
+Warping and material shrinking, especially in corners.
+
+### Proposed Solutions
+
+Add reheating steps at **140°C** and press again to minimize shrinkage and warping.
+
+| | |
+|-|-|
+| Mould | ![Mould](cas-650-hdpe-10.jpg) |
+| Top-side | ![Top-side](cas-650-hdpe-10.jpg) |
+| Back-side | ![Back-side](cas-650-hdpe-10.jpg) |
+
+---
+
+## 20 mm
+
+A two-stage process for thicker sheets with a more controlled heating and pressing cycle.
+
+### Description
+
+Two-stage process for enhanced material control and heating distribution.
+
+### Settings
+
+- Temperature: **155°C**, cooling at **130°C**
+- Duration: **90-100 minutes** for initial heating, **30 minutes** cool-down with die insertion
+
+### Requirements
+
+1. Reheat the plastic to **130°C**.
+2. Insert a die with **3-4 mm** thickness once melted.
+3. Cool the mold for **30 minutes** before opening.
+4. For thicker molds, ensure the press has **20 tons** of power.
+  
+### Results
+
+Reduction in warping and improved flatness by using intermediate dies.
+
+### Problems
+
+Requires a significant amount of time to ensure proper penetration of heat.
+
+### Proposed Solutions
+
+Incremental heating and die insertion at controlled temperatures to minimize air pockets.
+
+| | |
+|-|-|
+| Mould | ![Mould](cas-650-hdpe-20.jpg) |
+| Top-side | ![Top-side](cas-650-hdpe-20.jpg) |
+| Back-side | ![Back-side](cas-650-hdpe-20.jpg) |
+
+---
+
+## 40 mm
+
+A challenging process with long melting times, leading to potential warping and deformation.
+
+### Description
+
+3-stage process for very thick sheets. Manual handling needed to prevent air pockets and deformities.
+
+### Settings
+
+- Temperature: **175°C**
+- Duration: **2 hours** of heating, **3 hours** cool-down
+- Mould: **55mm**
+- Die: **10mm**
+
+### Requirements
+
+1. Heat to **175°C** for at least **2 hours** to melt the thick plastic layers.
+2. Insert a die (10mm) to ensure no air pockets form.
+3. Let the plastic cool with a **3-hour** rest while engaged with the die.
+4. Reheat corners at **140°C** and press again, for 15 minutes, with no mould (careful).
+
+### Results
+
+Height differences up to **5 mm** on die-engaged side.
+
+### Problems
+
+Long melting times, air pockets, and corner deformities leading to warping on one side.
+
+### Proposed Solutions
+
+Intermediate reheating and more controlled cooling periods to mitigate height differences.
+
+| | |
+|-|-|
+| Mould | ![Mould](cas-650-hdpe-55.jpg) |
+| Top-side | ![Top-side](cas-650-hdpe-55.jpg) |
+| Back-side | ![Back-side](cas-650-hdpe-55.jpg) |
+
+---

products/poly-mech/resources/material/hdpe/assets/washed-3-stage-1-40mm/readme.md

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+## Settings
+
+- **Mould Size**: 43 x 35cm x 2cm
+- **Mould height**: 55mm
+- **Mould sheets**: 1x sanded stainless | 1x polished stainless
+- **Mould release**: none
+
+- **Temp - UP**: 175
+- **Temp - DOWN**: 175
+- **Heat**: Cold Start
+
+- **Duration-Melt**: 110 min
+- **Duration-Pre-Cool**: 25 min (heater off)
+- **Duration-Cooling-Final**: 8h
+
+- **Preparation**: 1x layers: 11cm
+- **Excess**: none
+- **Method**: Mould frame, 3 passes (intial melt, die pressing, surface cure/melt)
+
+- **Die Material**: sanded stainless
+- **Die Penetration**: 10mm
+
+- **Thickness Error**: 2mm per 50cm
+- **Flatness Error**: 2mm per 50cm
+- **Final sheet thickness**: 40.0 mm
+- **Contraction / Shrinkage**: 10mm per 50cm
+- **Surface Quality**: good
+- **Air voids**: 2-4mm @ 80% of the inner section

products/poly-mech/resources/sheets/tests/2024_09_14_22_42_34.mp3-sum.md

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+
+
+# Summary of the Process for Plastics Manufacturing
+
+- **First stage or one-stage process** only
+- Suitable for **up to 10mm** material thickness
+- Precision **not necessary** in this case
+- Plastic will **shrink in all dimensions** upon cooling
+  - Expect up to **10mm loss** in mold dimensions
+  - Thickness reduction of **1-2mm** 
+- Result: **Sheet press** no longer engaging the plastic, causing **warping**

products/poly-mech/resources/sheets/tests/2024_09_14_22_43_37-sum-sum.md

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+
+
+# Summarize, as Markdown, bullet points, determine chapter, mark times as **bold**
+
+- Start by placing stainless sheet inside mold with a precise fit.
+- Fill and press plastic slowly under heat (**HDPE: 155-160°C**).
+- For **10 mm** sheet: add **30 mm** plastic as mounting.
+- Avoid mounting edge touching the mold, prevents overflow during pressing.
+- Wait **10 minutes** before fully pressing sheet against plastic.
+- Plastic tends to stick and form well after this waiting period.
+- For **10 mm**, wait **1 hour** for mold to fully close.
+- Then reduce to **130°C**, wait another **30 minutes**.
+- Mold can be removed, turned around, and stainless sheet accessed easily.
+- Remove protection sheet, keep stainless one still connected to plastic.
+- Insert die or hard material, e.g., **gips carton** or stainless sheet (**3-4 mm**).
+- For **10 mm**, reheating is not usually necessary.
+- Press again to ensure a smooth, shiny, and flat result.
+- Wait **3-4 hours** before removing the sheet.
+- Sheet quality can vary based on plastic uniformity, cleanliness, and flake size.
+- Flatness errors of **0.5-1 mm** are common depending on press quality.

products/poly-mech/resources/sheets/tests/2024_09_14_22_48_49-sum-sum.md

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+
+
+# Summary of the two-stage process for molds
+
+- **10 millimeter molds**:
+  - Use a die between 3-4mm.
+  - Place a 2mm protection sheet inside.
+  - Ensures perfect flatness and surface quality.
+
+- **20 millimeter molds**:
+  - Requires a bit more complexity.
+  - Melt for **90-100 minutes** at **155°C**.
+  - Use at least a 3cm mold with an 8-10mm die.
+  - Requires heating to around **130°C** (30°C below melting point), ensuring plastic relaxation and optimal die performance.
+
+- **Press setup**:
+  - A press with **20 tons** of power is ideal, more power would be beneficial for higher molds.

products/poly-mech/resources/sheets/tests/2024_09_14_22_51_39-sum-sum.md

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+
+
+# Summarize, as Markdown, bullet points, determine chapter, mark times as bold 
+
+- **Two-stage process** for **3 cm** plastic sheets
+- Needed materials:
+   - **4 cm mold**
+   - Frame thickness: **at least 2 cm**
+   - Die: **min. 10 mm**
+- **Heating**:
+   - Reheat plastic to **130-140 °C** before melting
+- Avoid squeezing plastic under mold
+- Fill mold with **8-10 cm** hand-pressed mountain
+- Ensure no excess material leaves the mold
+- Cool down for **30 minutes** for **4 cm flat sheets**
+- Insert die at **140 °C**
+- Watch pressing process carefully
+- Result: Likely **up to 1 mm** flatness error

products/poly-mech/resources/sheets/tests/2024_09_14_22_54_22-sum-sum.md

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+
+
+# Summarize, as Markdown, bullet points, determine chapter, mark times as **bold**
+
+- Used 55mm high mold; struggle with timings and temperatures.
+- **155°C** was insufficient to penetrate 12cm of plastic, melting took around **2 hours**.
+- Inserted die; air pocket built up in the center.
+- Handled air pocket manually; had **3 tests**, final one was slow but had corner deformations due to deformable die.
+- Cooled to **120°C**, let it rest for **3 hours** with die engaged, still had deformations.
+- Reheated surface at **140°C** for **10 minutes** to melt away corner deformations.
+- Warping observed on one side with corners **1 cm** higher, but one side kept flat.
+- Die-engaged side had **5mm** height difference.
+- Carefully melted corners to remove excess but avoided over-melting to prevent sheet skewing.
+- Monitored sheet thickness throughout to ensure uniformity.