The present invention is directed to a modified polypropylene comprising from 0.3 to 2 long-chain branches per 1,000 carbon atoms, wherein said long-chain branch has more than 1,000 carbon atoms and 0 to 6% of ethene and/or alpha-olefinic comonomer having 3 to 18 carbon atoms. The polypropylene of the present invention is a homopolymer, a random copolymer, or a heterophasic copolymer. The present invention also relates to large, deep, complex and/or thick articles which are thermoformed from said polypropylene. Furthermore, the present invention relates to the process for thermoforming said modified polypropylene into large, deep, complex and/or thick articles. The present invention also relates to the use of the polypropylene to prepare large, deep, complex and/or thick articles.

A thermoforming system and related methods for manufacturing thermoplastic parts, such as interior panels for aircraft, may include a roll-to-roll operation and a forming press having at least one selectively rotatable tool. The rotatable tool, which may include a mold and/or a die, may be multifaceted, such that different faces of the tool have different mold arrangements for different forming characteristics.

Personal watercraft and personal watercraft fabrication using a thermoforming process are described. The personal watercraft manufacturing process includes a set of molds, thermoforming equipment, and thermal formable materials. The process greatly reduces manufacturing costs, decreases manufacturing time, increases part consistency and tolerances, offers better performance characteristics and durability and results in less environmentally harmful deposits and waste.

Personal watercraft and personal watercraft fabrication using a thermoforming process are described. The personal watercraft manufacturing process includes a set of molds, thermoforming equipment, and thermal formable materials. The process greatly reduces manufacturing costs, decreases manufacturing time, increases part consistency and tolerances, offers better performance characteristics and durability and results in less environmentally harmful deposits and waste.

The present invention is directed to a system for thermoforming a batch of dental appliances simultaneously. An embodiment of the invention includes a vacuum plate having an upper surface and a plurality of cups for receiving dental models. A polymer sheet extends over the upper surface of the vacuum plate and over the cups. A heater cap that is movable in proximity to the cups is provided to heat the polymer sheet to be formed onto the dental models. The vacuum plate is configured to create a vacuum seal between an upper edge of the cups and the polymer sheet. A vacuum source is provided to apply a vacuum to the cups below the polymer sheet wherein the pressure contained in said cups is lower than atmospheric pressure whereby at least a portion of the polymer sheet is drawn into each of the cups and drawn over the dental models to form an aligner over each of the dental models. The invention includes the process of drawing a vacuum in a series of steps, or phases, to the cups below the polymer sheet to form the polymer effectively around the dental model.

The present invention is directed to a system for thermoforming a batch of dental appliances simultaneously. An embodiment of the invention includes a vacuum plate having an upper surface and a plurality of cups for receiving dental models. A polymer sheet extends over the upper surface of the vacuum plate and over the cups. A heater cap that is movable in proximity to the cups is provided to heat the polymer sheet to be formed onto the dental models. The vacuum plate is configured to create a vacuum seal between an upper edge of the cups and the polymer sheet. A vacuum source is provided to apply a vacuum to the cups below the polymer sheet wherein the pressure contained in said cups is lower than atmospheric pressure whereby at least a portion of the polymer sheet is drawn into each of the cups and drawn over the dental models to form an aligner over each of the dental models. The invention includes the process of drawing a vacuum in a series of steps, or phases, to the cups below the polymer sheet to form the polymer effectively around the dental model.

Processes and systems for thermoforming articles of wear are disclosed. The process can include utilizing a negative pressure generation system to seal an article in a forming material thereby compressing the forming material onto the outer surface of the article. The process can also include exposing the sealed article to an increased temperature followed by exposure to a decrease temperature, while maintaining the compressive force of the forming material on the outer surface of the article. A positive pressure can also be applied to the sealed article while undergoing the heating and/or cooling steps, which can facilitate the removal of bubbles from the article during thermoforming as well as apply additional compressive force to the outer surface of the article.

Processes and systems for thermoforming articles of wear are disclosed. The process can include utilizing a negative pressure generation system to seal an article in a forming material thereby compressing the forming material onto the outer surface of the article. The process can also include exposing the sealed article to an increased temperature followed by exposure to a decrease temperature, while maintaining the compressive force of the forming material on the outer surface of the article. A positive pressure can also be applied to the sealed article while undergoing the heating and/or cooling steps, which can facilitate the removal of bubbles from the article during thermoforming as well as apply additional compressive force to the outer surface of the article.

A thermoforming mold trimming system, apparatus, and method of use are disclosed. The thermoforming mold trimming apparatus includes a robot support structure with at least one robot secured to the robot support structure. The apparatus also includes a contact probe removably secured to the robot, the contact probe being configured to generate a trim path for a thermoformed molded part. The robot is programmed to follow the trim path generated by the contact probe. The robot then uses a blade to trim excess material of a finished molded part within the housing by following the trim path.

A method for manufacturing an automotive interior component may include providing a cover, a substrate, a chute connected to the substrate, heating the cover, forming the cover via a negative vacuum forming tool, and supporting the substrate and chute via a buck. The method may include moving at least of the negative vacuum forming tool and the buck toward the other of the negative vacuum forming tool and the buck such that the cover and the substrate may be in contact with each other. The method may include bonding the substrate with the cover via providing pressurized fluid to a chamber of the buck to force the substrate toward the cover. The chamber may be defined by the buck and the substrate.