2023 ASEE Annual Conference & Exposition

The project described in this paper involved undergraduate mechanical engineering students. Thin-gauge thermoforming is a process used to manufacture plastic blisters, cups, containers and other products for retail. The paper presents the design, building and testing of a thermoforming apparatus together with Ansys Polyflow simulations of the draping process. Theoretical results are presented in comparison with experiments and simulations for the stretching aerial and linear draw ratios and thickness reduction of the formed product. Finally, the paper will include a description of the outcomes for the project, student involvement and response, and an assessment of student learning.