Plastic manufacturing and fabrication involve expertise in many manufacturing processes. Plastic bending or line bending is one of the many plastic manufacturing processes. It is utilized to bend the plastic material or plastic sheets in a straight line in order to manufacture plastic products. Line bending is basically a malleable thermoforming process. It requires softening of plastic sheets until it reaches specific malleability by heat-treating the plastic material. Once the plastic is softened then it can be bent using a jig fixture or a former. This plastic forming process is absolutely precise yet demands very limited tooling. This process is employed for the manufacturing of products like display stands, binder’s acrylic tables, medical equipment, and casings, etc. Although the process of line bending sounds easy it is quite a contradictory scenario. It demands skilled operators and quality equipment for precise quality plastic product manufacturing. Ehren -Haus Industries, Inc. offers plastic line bending services for a broad range of plastic materials.
Line bending is a rapid forming process. The simplicity of the line bending process allows us to assure short turn-around times. Line bending process being an easy yet effective plastic fabrication process offers customizability. The plastic products of various dimensions and various materials can be manufactured by using the line bending process.
What is Our Process?
We accept designs in IGS, CAD, and DXF formats. The designs are analyzed and discussed with the client for clarity. Any design changes are suggested in the initial stages. The prototype building begins after seeking their approval.
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At Ehren-Haus, we offer high-quality plastic bending services. Being a prominent plastic manufacturing services company, we have invested in technology over the years. The following plastic bending capabilities allow us to serve our clients efficiently.
We are well-equipped with the strip heaters, line bending jigs and fixtures, and automated bending machines. Thus, at our plastic production machine shop, we can bend plastic sheets under several configurations like single fold, dual fold, multifold, etc. Due to multi-foldability, we can go for complex product designs.
We are equipped with industrial ovens and heaters, which helps us provide temperature variable line bending for a varying range of polymers. For example, we perform, line bending for ABS at a temperature range of 127° C to 204° C. whereas, for PMMA, the temperature range varies from 149° C to 218° C.
Our machine shop is equipped with automatic bending machines, which allow rapid line bending production. For bulk manufacturing, we opt for plastic bending automatic bending machine so that dimensional equality, bend angle precision, etc are achieved.
Our operators are well-versed with the line bending technique. Therefore, we can perform precise, quick, and multifold/multi-bend production by using a basic single strip heater. Owing to this quality, we are capable of line bending even without any advanced equipment.
Despite line bending being a thermoforming process, the polycarbonate materials like PETG can be cold bent. In this process, the material is not heated to soften but is bent on the strip heater. Break press is used for performing cold bending. At Ehren-Haus we perform cold line bending for specific materials.
We use advanced equipment for line bending, which enables us to customize the intricate designs online bent products. Owing to our efficiency in precise single and multifold line bending, we can manufacture plastic products with various edge angles and dimensions.
We are capable of bending plastic material sheets of a total length up to 2440mm and of thickness range from 2mm to 20mm. The thickness and length of plastic and thickness of the plastic sheet vary according to the product requirements.
Several complex line bent or plastic bent products feature two different bent shapes, which are fused through chemical or adhesive bonding. In this type of bonding, a strong adhesive or a chemical is used to bond the two bent shapes. Generally, an adhesive is applied between the shapes and fusion occurs due to the curing of a bonding agent at a specific pressure, heat, or time.
One typical way of bending plastics without breaking it is by utilizing heat. There are 3 basic rules to using heat: don’t heat too fast, don’t heat too close to the heat source, and don’t force the bend. In other words, the plastic should be slowly heated slightly off or away from the heat source. When it can move with ease the plastic is ready to be bent. The desired bend should be held until thoroughly cooled to achieve the desired bend.
Bending plastic, thick or thin, utilizes a lot of science and a bit of art. Typically, most thick plastics can successfully be bent using heat. A piece can be placed slightly above or between a medium heat source (such as a heat bar or coil) or even in an oven. But it should never be placed directly on the heat! This is where the art comes in: Attention must be paid to how the material is reacting – softening should occur slowly, without changing the color or surface of the piece. One wants to avoid inflicting stress or over stretching of the polymer. Once it has slowly softened all the way though it is then ready to be bent. Avoid high quick heat and forced bends. These can increase the probability of material stress in the material. Stress presents itself as turning white or crazing (crystallizing) within the material.
The quick answer is: Sometimes – it depends on how it got out of shape in the first place. If the piece shows little or no signs of stress, discoloration or crazing, then it could be possible to bend back into shape. Slowly heating some plastics can allow for gently reshaping the part.
Corrugated plastics are not typically bent with traditional heating methods. Scoring or slitting corrugated plastic creates the most aesthetically acceptable and reliable bend in corrugated plastics.
Techniques for reshaping plastics vary and depend on what type of plastic needs to be reshaped. How it became out of shape also plays a part in determining what can be done to reshape the plastic. Heat and pressure when applied together typically successfully reshape most plastics.
At Ehren-Haus, we offer plastic sheet bending services to meet the diverse bending requirements of our clients. We believe that the following benefits offered by our line bending services have contributed to their immense popularity.
Since the process of line bending demands no special-purpose machinery, it is quite a cost-efficient process. The cost of material and jig or fixtures along with heating devices add up to a comparatively less expense of other plastic forming processes.
The line bending process may be simple but it requires experience and expert operators. We have operators with over 25 years of experience in line bending. Therefore, we can offer extremely precisely dimensioned products with optimum quality.
Only tool requirement in line bending is a strip heater and bending fixture. However, we have equipped our machine shops with automatic bending equipment so enhance the speed, quality, and product uniformity in our line bending services.
Our production is compliant to ISO 9001 and ISO 9100 quality standards, which allows us to stay true to our quality commitment.
Are you looking for experienced and trusted custom plastic bending services for bending acrylic, polycarbonate, ABS and other plastic sheets? If yes, then you can totally trust us. If you intend to source the line bending or any other plastic engineering services including plastic fabrication, vacuum forming, cnc machining, acrylic fabrication, abs fabrication, then please feel free to contact us today.