Usage and Fabrication Guidelines INDEX MACHINING……………………………………………………………………………..…………………….…………………….2 General Rules Cutting Stamping and Die Cutting Sawing Drilling Holes Routing and Milling SURFACE TREATMENT………………………………………………………………….………………………………………..3 Surface Preparation Screen Printing Painting Varnishing Glues and Adhesives PHOTO MOUNTING AND LAMINATING………………………………………………..………………………………..5 THERMOFORMING………………………………………………………………………………………………………………….
Usage and Fabrication Guidelines MACHINING Foam can be used in the fabrication of variety of artifacts using common tools and machinery as recommended in this section. General Rules When machining Foam with high-speed equipment, using carbide tipped tools is recommended. Lower speeds usually work better and always use sharp tools to ensure smooth edges. Cutting Sheets of Foam up to 3 mm thick can be cut with a utility knife. Table and band saws, including routers, can be used to cut thicker gauges.
Usage and Fabrication Guidelines Drilling Holes Holes may be drilled through Foam using the same methods employed for drilling wood. Carbide tipped drills are recommended with a point angle between 90 degrees and 110 degrees and with a spiral angle of 30 degrees. (see illustration 3). High feed and drilling speeds may hinder the efficiency of the drill by creating heat buildup. For best results, use sharp bits and lower speeds. Routing and Milling Foam may be slotted, beveled, rabbeted, etc.
Usage and Fabrication Guidelines blow type heat gun is recommended to reduce the change of the scratch showing through the ink. Please refer to Table 1 for a list of preapproved ink manufactures. Painting In addition to screen printing, Foam also has the perfect surface for paint adhesion. There is no need to prime the surface before painting. Most conventional tools and painting methods will work successfully with Foam.
Usage and Fabrication Guidelines Glues and Adhesives There are a variety of solvent-based glues and adhesives in the market that can be used bonding Foam to itself and other materials. For best results, InteFoam sheets must be dry, clean and free of oil or grease. MEK (Methyl Ethyl Ketone). THP (Tetra Hydro Furan) or common PVC pipe glues work well. Make sure glue joints have a close fit tolerance.
Usage and Fabrication Guidelines THERMOFORMING Foam is a thermoplastic. It becomes soft when exposed to intensive heat. This characteristic gives the material thermoforming capabilities. However, since it is expanded PVC foam, it is important to know that it lacks the draw depth of solid PVC sheets. Heat bending, pressure and vacuum forming are among the methods that may be used to thermoform Foam.
Usage and Fabrication Guidelines WELDING There are several methods for welding plastics. The most common are butt welding and hot air welding or gas welding. Note that welds on expanded PVC foam are usually not as strong as those of solid PVC Butt Welding Butt welding is recommended for gauges 4mm and over. This method allows fusion by simply joining two ends together under pressure after ends have been heated to an optimum bonding state.
Usage and Fabrication Guidelines outdoor direct installation to concrete or metal surfaces may cause deflection. Please read the following instructions carefully. Free Hanging Signs When installing free hanging signs such as aisle markers in supermarkets, bookstores, and home centers, locate holes 1” or more from the vertical edge and at least ¾” from the horizontal edge. Use grommets to prevent wear and stress. The supporting chains should be installed at a 30 degree to 45 degree angle.
Usage and Fabrication Guidelines If wind shear forces are a consideration, using large diameter washers is recommended to spread the load forces over a larger area. WEATHERABILITY Due to the natural UV inhibitors in white Foam, it tends to perform very well in outdoor conditions. Colors have the tendency to fade over time when exposed to direct sunlight. However, Foam colors perform the best in the industry. Several years of research have resulted in formulations that make Foam colors stand out.
Foam TECHNICAL SPECIFICATIONS: I. TYPICAL PROPERTIES PROPERTY PHYSICAL Specific Gravity Water Absorption Shore D Hardness TEST METHOD UNIT VALUE ASTM D 792 ASTM D 570 ASTM D 2240 g/cm^3 % __ 0.75 .30 52 ASTM D 638 ASTM D 638 ASTM D 790 ASTM D 256 ASTM D 149 psi .% Psi ft lb/in^2 kv/mm 3,000 15 130,000 7 12 °F In/in/°F Btu in/hr ft^2 °F 140 35 x 10^-6 0.
Material Safety Data Sheet Manufacturer 1. PRODUCT INDENTIFICATION Product Name Product Code Chemical Family Chemical Name CAS No PVC Sheet Inte001 Vinyl Polymers Polyvinyl Chloride Sheet N/A Integral Skin Expanded Foam PVC Sheet Clear PVC Sheet Rigid PVC Sheet (Type I and II) Expanded Foam PVC Sheet Proprietary 512-874-3760 Formula Technical Information 2. PRODUCT INGREDIENTS No. 1 2 3 4 Components PVC Sheet Calcium Carbonate Titanium Dioxide Proprietary CAS No.
4. FIRE HAZARD DATE AND FIGHTING METHOD Flash Point Autoignition Flammable Limits in Air (LEL, %) (UEL, %) Extinguishing Media Special Fire Fighting Procedure Unusual Fire and Explosion Hazards n/a n/a n/a n/a Dry chemical, foam water, or carbon dioxide In the event of a fire, wear NIOSH approved, positive pressure, selfcontained breathing apparatus (SCBA) and full protective clothing. Evacuate all personnel from anger area. Use dry chemical, foam, water or carbon dioxide to extinguish fire.
7. EXPOSURE CONTROLS & PERSONAL PROTECTION RECOMMENDATIONS Eye Protection Skin Protection Respiratory Protection Engineering Control Required Work/Hygiene Procedure Exposure Guidelines No. Components OSHA-PEL ACGIH-TLV Wear safety glasses during sheet cutting or fabricating process.
12. TRANSPORT INFORMATION DOT Shipping Name DOT Label DOT Hazard Class UN/NA Number Hazard Label(s) Hazard Placard(s) Packing Group Bulk Packaging RQ Emergency Response Guide (ERG) No. Not listed Not applicable Not regulated Not applicable Not applicable Not applicable Not applicable Not applicable Not applicable Not applicable 13. TOXICOLOGICAL INFORMATION The information provided below can be subject to misinterpretation.
**Toxic chemical, Sec. 313. **Category as required by Sec. 313 (40CFR372.65C) must be used on Toxic Release Inventory Form. Section 311/312*** None ***Hazard category for SARA Sec.
