Investigation of a Combined Thermoforming and Welding Process

Since the design freedom of thermoforming is limited to shell-shaped components, functional elements such as screw bosses or ribs must be attached to the thermoformed component in a separate process step by bonding or welding. But a combined thermoforming and welding process could allow the direct application of design elements during the thermoforming process. In this process integration, not only process-specific parameters but also the respective material properties of the joining partners must be taken into account. Therefore, the effects and influences of various material properties and processing parameters on the quality of a welded joint were investigated, which were welded under thermoforming-specific processing parameters using an idealized welding equipment.