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Sheet thickness at deep drawing

How thick will the shell be, and what plate should I choose?

Answer: When a warm PP or PE sheet is drawn over a plaster model it doesn't make more plastic. The sheet is stretched over a larger area and gets thinner, most where it's stretched furthest, e.g. at heel and ankle on an AFO. The average wall thickness after forming is start thickness times sheet area divided by formed area. The calculator shows thinning and which sheet you should choose to end with a specific thickness.

Formula

Plastens volumen er den samme før og efter: tykkelse før × pladeareal = tykkelse efter × formet areal

Tykkelse efter = tykkelse før × pladeareal ÷ formet areal

Plade der kræves = ønsket tykkelse × formet areal ÷ pladeareal

Symbols and units in the formula
SymbolMeaningUnit
start_mmSheet thicknessmm
pladeareal_cm2Sheet area within the framecm²
formet_cm2Area of the formed surface (model + edge)cm²
oensket_mmDesired average thickness after formingmm
=Average wall thickness after formingmm
=Thinning%
=Sheet thickness giving the desired thicknessmm

Validity and source

Source
Volumenbevarelse ved termoformning: tykkelse efter = tykkelse før × pladeareal ÷ formet areal

Does not apply when

  • The figure is an average. The shell is thinnest at the highest and sharpest parts of the model and thickest at the edge. Measure shell thickness with a gauge at critical spots before grinding.

Worked example

The calculator's own default values inserted. The figures are calculated with exactly the formula the tool uses.

Substituted

  • Sheet thickness4 mm
  • Sheet area within the frame1,200 cm²
  • Area of the formed surface (model + edge)1,800 cm²
  • Desired average thickness after forming3 mm

Giver

  • Average wall thickness after forming2.67 mm
  • Thinning33 %
  • Sheet thickness giving the desired thickness4.5 mm

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Sådan bruger du den

Du bruger den, når du vælger pladetykkelse til en dybtrukket ortose, fx en AFO i polypropylen. Pladen bliver tyndere, når den strækkes over modellen.

Step by step

  1. Find pladens tykkelse.
  2. Mål pladens areal inden for rammen.
  3. Skøn eller mål arealet af den formede flade.
  4. Tykkelse efter = tykkelse før × pladeareal ÷ formet areal.
  5. Vælg en tykkere plade, hvis resultatet er for tyndt.

Typical errors

  • At regne med pladens tykkelse som skallens.
  • At glemme at de højeste dele bliver tyndest.
  • At varme pladen ujævnt.

Examples from everyday life

AFO i 4 mm PP

En plade på 4 mm og 1.200 cm² trækkes over en model, der giver 1.800 cm² formet flade.

Sheet thickness
4 mm
Sheet area within the frame
1,200 cm²
Area of the formed surface (model + edge)
1,800 cm²
Desired average thickness after forming
3 mm

It means: Den gennemsnitlige tykkelse bliver 2.67 mm, altså 33 % udtynding. For at få 3 mm i snit skal pladen være 4.5 mm.

Høj model

En plade på 5 mm og 1.200 cm² over en høj model på 2.100 cm².

Sheet thickness
5 mm
Sheet area within the frame
1,200 cm²
Area of the formed surface (model + edge)
2,100 cm²
Desired average thickness after forming
3 mm

It means: Tykkelsen bliver 2.86 mm i snit, med 43 % udtynding.

Rule of thumb

Bliver arealet halvanden gang større, bliver pladen to tredjedele så tyk.

How to check the answer

Mål skallen med tykkelsesmåler ved malleolerne og hælen.