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Fabricating and forming sheet
Durability, Sustainability, Flexibility
Contents
Fabricating and forming sheet 1
Generalhealthandsafetyprecautions 1
Storingandhandling 1
Cleaning 2
Sawing,routing,andlasercutting 2
Tipsforcutting 3
Drilling 5
Shearing,punching,anddiecutting 5
Bonding,fastening,andwelding 7
Tipsforbonding 11
Forming 12
Tipsforthermoforming 15
Decorating 16
Summaryoffabricatingandforming 18
Note: Conversion of metric/U.S. customary values may have been rounded off and therefore may not be exact.
Fabricating and forming sheet
EastmanSpectar™copolyester14471,alsoknownasPETG,
isaplasticresinspecificallydesignedforthicksheet
applications.ItisproducedinpelletformbyEastman
ChemicalCompany,andconvertedintosheetbyvarious
commercialextruders.
General health and safety precautionsSafetyAlwaysexercisegood,safeshoppracticeswhenfabricating
orformingsheetofEastmanSpectar™copolyesterand
otherplasticmaterials.Heatgeneratedduringsawing,
machining,finishing,andthermoformingoperationscan
burnunprotectedskin.Flyingparticlesandcontactwith
chemicalsandvaporsarealsoareasofconcern.Besureto
adherestrictlytoallinstructionsinMaterialSafetyData
Sheets(MSDS)providedbyequipmentandmaterial
suppliers.Inaddition,keeptoolssharpandingood
workingorderforsafeoperationandhigh-qualitywork.
VentilationItisalwaysgoodshoppracticetoworkinawell-ventilated
area,particularlywhensolventbonding,cementing,orlaser
cutting.Providelocalizedexhaustventingintheworkarea.
Protective equipment Alwaysuseappropriatesafetyequipment(goggles,gloves,
hearingprotection,etc.)whenhandlingplasticsheetand
operatingshopequipment.
Storing and handling Sheet stockHeavy-gaugeplasticsheetisgenerallyshippedincorrugated
cases,onpallets,orascontinuousrolls.Storelargesheet
flatwithmaskingintact.Sheetstoredonedgeinstorage
racksshouldhaveasupported,slightlyangledbackboard
(A-frame)topreventsheetfromwarping.Besurestorage
areasareclean,dry,cool,andwell-ventilated.Whenpossible,
rotateinventoriesonafirst-in/first-out(FIFO)basis.
MaskingSheetofEastmanSpectar™copolyesterisprotectedwith
amaskofpolyethylenefilm.Wheneverpossible,leavethe
maskingintactduringfabrication.Useolderstockfirst.
Also,avoidanyunsupportedoverhangofthesheetduring
storage.
Removeanymaskingadhesiveresidueonthesheetwith
aclean,softclothdampenedwitha50:50mixtureof
isopropylalcoholandwater.Ifthesheethasastaticcharge
afterremovingthemasking,wipethesheetwithaclean
clothslightlydampenedwithwatertohelpremovethe
charge.
Handling formed partsFormedpartswillcontinuetocoolaftertheyareremoved
fromthemold.Topreventdeformation,itisimportantto
providepropersupportduringcooling.Also,avoidany
unsupportedoverhangoftheflatsheetorformedparts.
Topreventdishing(becomingconcave),supportpartsalong
theiredges,facedown,untilcompletelycooled.Donot
nest-stackformedparts.
General handling and storage recommendations•Weargloveswhenhandlinglargesheetstopreventcuts.
•Keepmaskinginplaceforaslongaspossible.
•Keeptabletopscleantoavoidscratchingthesheet.
•Storesheetsflat,asdelivered,topreventwarpage.If
verticalstorageisnecessary,itisbesttostorethesheet
andformedpartsataslightanglewithfullsupport
underneath.
•Supportlarge,formedpanelsbytheiredges,facedown,
whilecooling.
•Storematerialindoorsinadry,cool,well-ventilatedarea.
•UsetheFIFOmethodtorotateinventory.
•Donotuseaknifeorscrapertoremovemasking.
•Donotstoreplasticsheetnearradiators,steampipes,or
indirectsunlight.
1
CleaningDust and dirtRemovedustanddirtfromsheetofEastmanSpectar™
copolyesterwithasoftcottonclothandasolutionofmild
soaporliquiddetergentinwater.A50:50solutionof
isopropylalcoholandwateralsoworkswell.Remove
greaseandresiduefromtapeorpapermaskingwith
naphthafollowedbyawaterwash.Alwaysuseasoft,
dampclothandblotdry.Rubbingwithadryclothcan
scratchthematerialandcreateastaticcharge.Neveruse
scrapersorsqueegeesonSpectarsheet.Seeadditional
cleaninginstructionsonpage16.
Do NotUse a squeegee.Use strong solvents.Rub with a dry cloth.
Sawing, routing, and laser cuttingGeneral recommendationsIfpossible,leavetheoriginalmaskingonthesheetduring
cuttingoperations.Inaddition,coverworkingsurfaceswith
asoft,cleanclothtopreventscratching.
Usesharp,cleanblades,holdingthesheetsecurelyinplace.
Bringthebladetofullspeedbeforestartingthecutand
usecompressedairtocoolthebladeandremovechips.
Wearpropersafetyequipmentincludingsafetyglasses,
gloves,andprotectiveclothingasrequiredbyapplicable
regulations.
Saw and cutter typesMostsawscommonlyusedforwoodormetalshould
satisfactorilycutsheetofEastmanSpectar™copolyester.
Theseincludecircularsaws,bandsaws,sabersaws,jigsaws,
hacksaws,orhandsaws.However,circularsawsandband
sawsusuallyproducesmoother,cleaner,fastercuts.
Routingisalsoacommontechnique.
Forthehighestqualitycut,useatriple-chipstylecarbide-
tippedbladecommonlyusedforplastics.SeveralSpectar
sheetscanbestackedandcuttogetherbutonlyifthe
stackisheldsecurelytopreventmovementfromsheetto
sheet.Otherwise,chippingandirregularcutsmayresult.
Useaslowandconsistentfeedrate.
Blade characteristics Circular saws
•Numberofteeth—2to4teethper25mm(perinch).
•Bladethickness—2.5mm(3⁄#@in.)forsinglesheetsin
thicknessesof1to10mm(0.040to0.375in.);3-mm
(l-in.)bladeshouldbeusedforcuttingthickersheet.
•Bladetoothrakeangle—0°–5°.
•Depthofcut—forbestresults,allowthebladeto
protrudethroughthepiecebynomorethan3mm
(lin.).Thiswillminimizethechanceofcreatinga
chippededge.
•Forcircularsaws,thefollowingbladespeedsare
recommended.
Blade diameter, mm (in.) Blade speed, rpm
100(3.5–4)Trimmingsaw,usewoodcombinationblade
10,000
180(7d) 5,000
200(8) 4,300
250(10) 3,400
300(12) 2,900
350(14) 2,500
Band saws
•Numberofteeth—8to14teethper25mm(perinch)
forgeneralcutting;18to24per25mm(perinch)fora
smoother,cleaneredge.
•Bladewidth—forintricatecutsandtighterturns,
6to10mm(dtomin.)issuggested.Forstraightcuts,
largerturns,12to25mm(ato1in.)issuggested.
•Bladespeed—approximately760mm(2,500ft)
perminute.
Saber saws and jigsaws
Alwaysholdyourworksecurelyinplace.Thisisespecially
importantwhenusingasabersaworjigsaw.Excessive
vibrationcancausecrackingand/orpossibleinjury.
•Abladewith6to10teethper25mm(perinch)works
wellwiththeorbitalactionsettingatzero.
•Ascroll-typebladewith12to20teethper25mm
(perinch)canbeusedtoachieveagoodedgefinishon
intricatecuts.
2
Handsaws and hacksaws
AlthoughnotcommonlyusedonsheetofEastman
Spectar™copolyester,handsawsandhacksawscanwork
satisfactorilyifusedcarefullyandwithlittlepressure.Use
sharpbladesthatrangefrom6to18teethper25mm
(perinch),dependingonthedesiredfinish.Asalways,
securelysupportthesheettoavoidflexing.
Routers
Routingwithsharp,two-flute,carbide-tippedstraight
cuttersproducesverysmoothedges.Twistedtwo-fluted
cuttersworkexceptionallywell.Alsospiral-cutrouterbits
havebeenfoundtoworksuccessfully,dependingonthe
application.Itisespeciallyusefulfortrimmingedgesofflat
orformedparts,orpartstoolargeorirregularinshapeto
cutwithabandsaw.Portable,overarm,andsmalltable
routersworkequallywell.
•Userouterspeedsof18,000–32,000rpmtoproduce
good,cleanedges.
•Feedthesheetintotherouterslowlytoavoidexcessive
frictionalheating,shattering,orchipping.
•Useasuitablejigtosupportthesheetduringrouting.
•Usecompressedairtocoolthebitandtoaidinchip
removal.
Laser cutting
EastmanSpectar™copolyestercanbelasercutusingthe
sameequipmentasthatusedforcuttingacrylic.Typically
lowerpowersettingsandslowercuttingratesarerequired
whencuttingSpectarsheetvs.acrylicsheet.Itisalso
recommendedthatacuttingtablewithgoodvacuum
ventilationbeutilizedtoremovetheby-productscreated
duringthecuttingprocess.ThisappliesforbothSpectar
andacrylicsheet.
Eastmaniscurrentlyworkingwithlaserequipmentto
betterunderstandthelasercuttingsystemwhenworking
withSpectarsheet.PleasecontactEastmantechnical
serviceforfurtherupdates.
Tips for cutting Eastman’srecommendationsarebasedonexperience
workingwithsheetofEastmanSpectar™copolyester.They
canbeusedasastartingpointorasguidelinesforcutting
theseproducts.
•Usetoolsdesignedforplastic.
•Usesharpblades:Jigsawsshouldbeequippedwitha
scroll-typebladefordetailworkandacoarse-toothed
bladeforbetterchipremovalonheavierwork.Forcircular
saws,acarbide-tipped,triple-chiptoothpatternis
recommended.
•Holdsheetfirmlywhilecuttingtominimizevibration,
especiallyforthinnergauges(<120mil).
•Keepfeedrateslowandconstantwhencutting.
•Donotreversethenaturalcurveofthematerialwhen
cuttingsheetfromrollstock.Thisoverstressesthesheet
andcancausefractures.
3
Router speeds of 18,000–32,000 rpm should produce good, clean edges.
Operation Type of equipment Recommendations
Trimming
Routerbitsd-inchminimum,single-ordouble-flutedup-spiralbitsarerecommended,3–4flutedforlargerbits(i.e.,Onsrud#52-624).
Routerblades4-Wingcarbidetip,slottingcutter(i.e.,WhitesidePart#6700B),>20Krpm,slow/medcutspeed
Jigsaw Recommend10teeth/inchforsmoothestcut
Bandsaw Recommendminimumof6teeth/inch
Circularsaw(3.5–4-diameter)
Carbide,triple-chiptoothcutrecommendedifcanfind,otherwiseuseawoodcombinationblade(i.e.,Makita),2mm-rake,>10Krpm.
Circularsaw,7-diameter 60-toothcarbide-tippedblade,triple-chiptoothcutifpossible
Roto-ziptypeZB10bitforsmalltrim(<=0.150-sheet),Onsrud#52-624for(>=0.150-sheet)
KettsawBlade#157-66,2.5,80teeth,rateofcutwilldeterminequalityofcut,keepsharpbladetopreventmeltingplastic
Drilling Drillbits Thosenormallyrecommendedforplastics
Recommendations for cutting sheet of Eastman Spectar™ copolyester
Problem Possible cause Possible solution
Roughorchippededges
HighfeedrateSheetvibrationBladeprotrusionBrokenteethBladetoocoarse
Reducefeedrate.Securesheetfirmly.Limittomaximumof3mm(l in.).Replaceblade.Usemoreteeth/in.(mm).
CrackingBladeandfencenotparallelSheetvibrationFeedratetoohigh
Realignbladeandfence.Securesheetfirmly.Reducefeedrate.
SurfacescratchingNomaskingDirtyworksurfaceJigs/fixturesarenicked,burred
Ifpossible,leavemaskingintact.Cleanworksurface.File,sand,orpolishtoremoveburrs.
Bladegumsup
DullbladeInconsistentfeedrateFeedratetooslowImproperblade
Sharpenorreplaceblade.Usesteady,evenfeedrate.Increasefeedrate.Usebladespecified.
Dustbuildup
DullbladeCloggedbladeStaticchargeonsheetMaskingremoved
Sharpenorreplaceblade.Cleanorreplaceblade.Wipewithdampcloth.Leavemaskinginplace.
4
Troubleshooting guide for cutting sheet of Eastman Spectar™ copolyester
Knife edge Hollow groundapproximately
Sheet thickness up to2.5 mm (0.100 in.)
5
DrillingDrills and bitsSheetofEastmanSpectar™copolyestercanbereadily
drilled,usingastandarddrillpressorhandhelddrillwith
sharp,cleandrillbits.Drillbitsdesignedforusewithplastic
arerecommended.Bitsdesignedforusewithpolycarbonate
havebeenfoundtoworkwellwithSpectarsheet.Standard
drillbitscan,onoccasion,beusedbutmayhavetobe
groundtoreducethedepthorangleofcut.Aswithany
plasticsheetproduct,itisimportanttokeepvibrationto
aminimumtopreventchippingorcracking.Holdthework
securelyinplacewhendrillingbutavoidexcessive
clampingpressure.
Drilling procedureOptimumbitspeed,feedrate,andappliedpressurewill
dependonholesizeandsheetthickness.Drillspeedsupto
1,750rpmarebestforsmallerholes,whilespeedsaslow
as350rpmcanworkforlargerholes.Usewateror
compressedairtominimizeheatbuildupwhendrilling
sheetsthickerthan4.8mm(0.187in.),stackedsheets,
orverylargeholes.
Whendrillingholesthatwillpenetratethesecondsurface,
backupthepiecewithwoodtocushionthedrillbitasit
passesthroughthesheet.Movethedrillbitinandoutto
removeplasticshards.
Avoidtoppingadrilledholeorusingself-toppingscrews.
Summary•Usesharpdrillbitsdesignedforplastic.
•Usejustenoughclampingpressuretopreventvibration.
•Usealoadspreadertodistributeclamppressureevenly.
•Usecompressedairtopreventoverheating,especiallyif
sheetismorethan4.8-mm(0.187-in.)thick.
Shearing, punching, and die cuttingGeneral recommendationsSheetofEastmanSpectar™copolyesterisatoughbut
ductilematerialandcanbesheared,punched,anddiecut
whenpropertoolsandtechniquesareused.Ashearcut
yieldsastraightedge,whilepunchesanddiescanbeused
toproduceholesofalmostanydesiredshape.
ShearingApowershearcanbeusedtocutsheetinthicknesses
upto2.5mm(0.100in.).Forthickersheet,sawingis
recommended.Toachievesmoothcuts,maintaina
blade-to-bedknifeclearanceofapproximately0.025mm
(0.001in.).Thefollowingdiagramshowsatypical
shearingassembly.
Thickness, mm (in.) Sheet shear strength, MPa (psi)
2(0.080) 57.6(8,354)
3(0.118) 56.5(8,195)
Shear strength requirements (ASTMD732,shearstrengthdeterminationmethod)
Shear strengthThefollowingtableshowsshearstrengthrequirementsfor
cuttingvariousthicknessesofsheetofEastmanSpectar™
copolyester.
PunchingWhenaparticularlysharporsmoothcutisnotrequired,a
punchcanbeused.Hand-operatedpunchesareusefulfor
smallholes,butlargerholesmayrequireapower-operated
punch.Heatingthesheettoapproximately38°C(100°F)
willminimizethepossibilityofcrackingorchipping;
however,allowforholeshrinkageduetocooling.We
recommendsawing,drilling,androutinginsteadof
punchingsheetthickerthan2.5mm(0.100in.).
Die cuttingCut0.8-to2.5-mm(0.030-to0.100-in.)thicksheetof
EastmanSpectar™copolyesterwithsteelruledies.These
areusually12.5-mm(a-in.)deepandaremountedina
properlyshapedslotcutintoawoodenblock(seethe
followingdiagram).Whilerelativelyinexpensive,steelrule
diesmustbesharpenedorreplacedfairlyoftentoremain
effective.
Apply pressure
Knive edge
Hollow ground
approximately 30°
Cut 0.8- to 2.5-mm(0.030- to 0.100-in.)thick sheet of Eastman Spectar™ copolyester with steel rule dies.
Die press capacityAdiepressmusthaveadequatepowertoachievethe
desiredcut.Usetheshearstrengthsshownonpage5
withthefollowingformulatocalculatetherequired
presscapacity.
F=SXPXT
CF=Requiredpresscapacityintons
S=SheetshearstrengthinMPa(psi)
P=Perimeterofcutinmm(inches)
T=Thicknessofsheetinmm(inches)
C=8,896N/ton(2,000lb/ton)
Example
A3-mm(0.118-in.)thicksheetofEastmanSpectar™
copolyesterrequiresashearstrengthof56.5MPa
(8,195psi).Thepresstonnagerequiredtodiecutasheet
measuring381-mm(15-in.)squareiscalculatedinthe
followingequation.Theperimetermeasurementis
calculatedbymultiplying381mm(15in.)X4because
theshapeissquare.
F=(56.5MPa)(3mm)(1,524mm)=29ton
8,896N/ton
SI units
NOTE:Theactualcuttingforcerequiredtocutthroughathickersheetincreaseswithaddedsheetthickness.Shearstrength(psi)iscalculatedbydividingthecuttingforcebytheshearedarea.
F=(8,195psi)(60in.)(0.118in.)=29ton
2,000lb/ton
U.S. customary units
However,assheetthicknessincreases,theshearedarea
(sheetthicknessXcutlength/perimeter)overwhichthe
cuttingforceisdistributedincreasesatagreaterratethan
themagnitudeoftherequiredcuttingforce,thuscausing
theshearstrengthvaluestodecreasewithincreasing
thickness.
6
Die designDesignsfor2steel-rulecuttingedgesthatworkequally
wellwithsheetsupto2.5-mm(0.100-in.)thickareshown
below.Steelhardnessshouldbe45to55RockwellC,
dependingonthedegreeofbendingrequiredinfabrication.
0.030�
30°15°
5°
10°
0.012� 0.045�
30°
30°
0.020�
Die cutting procedureAdjustthepresstomakeacompletecutinasinglestroke
withoutdamagingthedie.Shimthedieasnecessaryto
ensurethatallareascutuniformlythroughthesheetof
EastmanSpectar™copolyester.Toensurethattheentire
dieislevelandtrue
•TapeKraftorcarbonpaper,150-to200-mm
(0.006-to0.008-in.)thick,totheplate.
•Lowerdietomarkanimprintofthecuttingpattern.
•Shimlowruleareas.
•Makeatestcut.
•Alternatecutting/shimminguntilafull,uniformcutis
obtained.
•Positiontestpartsconsistently.
•Keepcuttingdiesassharpaspossible.
Topreventcontactbetweenthedieandthepressbed,use
asteelcuttingplate0.5-to3-mm(0.020-to0.118-in.)
thickwithaRockwellChardnessof30to35.
Bonding, fastening, and welding Bonding methodsSolventbondingisgenerallypreferredwhenthe
componentstobejoinedaremadefromsheetofEastman
Spectar™copolyester.However,adhesives,mechanical
fastening,orplasticweldingmaybeneededwhenjoining
dissimilarmaterialsorconsiderationssuchaspartsize,
bondflexibility,orbondappearanceprevail.Recommended
adhesivesincludecyanoacrylates,two-partacrylics,
two-partpolyurethanes,andtwo-partepoxies.
Solvent bondingTheexcellentchemicalresistanceofsheetofEastman
Spectar™copolyesterallowsitsuseincertainapplications
whereotherplasticmaterialsmightbeunsuitable.This
featuremustbetakenintoaccountwhenchoosinga
solventforanoptimumbond.Useofapropersolvent,
goodtechnique,andcuretimeshouldresultinaclear,
haze-freejointthatisstronganddurable.Whetherusing
thecapillaryactiontechniquecommonlyemployedfor
smallerpartsandbondsoffairlyshortlengthorsome
othermethod,thepartsmustfittogetherwellwithout
forcing—leaving no visible gaps. Forthebestbonding
results,allowthesolventtofullypenetratetheedgesto
bebonded.
Solvent selectionThereareseveraloptionsforbondingsheetofEastman
Spectar™copolyestertoitself.Theseincludecommercial
productsaswellascustomblendsofMEKandmethylene
chloride.Youmayalsoconsultthesheetextruderoryour
distributorforadditionalsolventagentssuitableforuse
withSpectarsheet.
7
No gaps
Good
Shows gaps
Bad
Corner joint
Lap joint
MEK,afast-actingsolvent,givesquickersetupwithmore
likelihoodoffreeze-off(settingupbeforethejointisfilled).
Methylenechloride,ontheotherhand,isaslowersolvent
andoffersmoreworktimewithlesspotentialforfreeze-
off.Insomelocations,a50:50mixofmethylenechloride
andMEKisusedasastartingpointtoformulatecustom
solventblends.Asmallamountofaceticacidcanbeadded
whenbondinginhumidenvironments.
Somewater-thinformulasdesignedforbondingacrylics
canalsobeusedtobondsheetofEastmanSpectar™
copolyestertoitselfiftheyareusedwithcare.Weld-On™3
andWeld-On™4,availablefromIPSCorporation,aretwo
suchformulas.Hazingmay,however,occasionallybe
observed.
Donotusethickcementsintendedforusewithother
plastics;theyaregenerallyincompatiblewithSpectar
sheet.
•Useneedle-typeapplicator.
•Applysolventevenlyalongentirelength.
•Applyfrominsideforcornerjoints.
•Applyfrombothsidesforlapjoints.
Problem Possible cause Possible solution
Solventfreeze-off
UseofimpropersolventSwitchtoasystemdesignedforsheetofEastmanSpectar™copolyester.
Solventtooactive Dilutemixturewithaslowersolvent.
Applicationtechnique Reevaluatetechnique.
Hazy/cloudyjoints
Useoftoomuchsolvent Uselesssolvent.
Poorpartfit Improvepartfit.
Solventpooling Checklevelingofparttoreducepooling.
Oldsolventmixture Addfreshsolvent.
Weakjoints
UseofimpropersolventSwitchtoasystemdesignedforSpectarsheet.
Applicationtechnique Reevaluatetechnique.
Poorpartpreparation Preparepartproperly.
Voidsappearaspartcures
Useoftoomuchsolvent Uselesssolvent.
Poorpartfit Reshapepartstoimprovefit.
Solventpooling Checklevelingofpartsassolventisapplied.
PartshiftsduringsetupIncreaseclampingpressureand/oruseajigtoholdpartsinplacewhilebondsetsup.
Overlyroughsurface Lightlysandsurface.
8
Troubleshooting guide for solvent bonding
Adhesive bondingWhenjoiningdissimilarmaterials,solventbondsare
rarelystronganddurable,sotheuseofadhesivesisoften
recommendedforthispurpose.Theadhesiveselected
mustbecompatiblewitheachmaterialinvolved.
Ifthematerialsbeingjoinedexpandandcontractat
differentrates,aflexiblebondmayberequired.Takethis
intoaccountwhenselectingtheadhesiveformulation.If
expansionandcontractionareamajorconcern,consider
theuseofmechanicalfastening.
Adhesive characteristicsAvarietyofadhesivesareavailableforjoiningdissimilar
plasticmaterials.Asaresult,itisdifficulttomakegeneral
observations.Unlikesolvents,whichevaporate,an
adhesivelayerremainsafunctionalpartofthefinished
assembly.Hence,theperformanceandappearanceofthe
finishedpartmaydependprimarilyonthecharacteristics
oftheadhesivelayer.
Forexample,theselectionofabrittleadhesive,orone
thatcontainsaggressivechemicals,maylowertheimpact
strengthofsheetofEastmanSpectar™copolyester.Several
characteristicstoconsiderwhenselectinganadhesiveare
•Chemicalcompatibilitywiththepartsbeingjoined
•Aestheticsofthefinishedjoint
•Expansion/contractionwithtemperaturechanges
•Brittleness/rigidity/flexibility
•Weatherability,ifrequired
•Durability/servicelife
•Adhesivestrength(adhesiontotheplastic)
•Cohesivestrength(resistancetointernaltearing)
•End-userequirements
•Suitabilityforfoodcontact
Adhesive-bonding procedureJoinedsurfacesmustfitwellwithoutforcingandhaveno
visiblegaps.Thesurfacestobebondedshouldbesmooth
butnotpolished.Sandthesurfacestobejoinedwitha
120-gritorfinerpaper.Diamond-wheelpolishers,jointer/
planers,orothermechanicaldevicescanproduceexcellent
results.However,softpolishingwheelsorflamepolishing
arenotrecommendedasthesecanroundtheedges,
causinggapsandimproperfit.
Adhesive shrinkageSomeadhesiveswithavolatilecomponentmayshrink
whilecuring.Tocompensateforthis,cutthejointonan
angle,providingspaceforthejointtobeslightlyoverfilled.
Consultyouradhesivesuppliers’literatureforspecific
informationonshrinkage.
Angle to provide space for the joint to be slightly overfilled to compensate for shrinkage.
Overfill to allow for shrinkage.
9
Tips on adhesive bonding•UseanadhesivesystemtobondsheetofEastman
Spectar™copolyestertoothermaterialssuchasacrylic
orpolycarbonate.
–ForbondingsheetmadewithSpectartoitself,use
Weld-On™58,Weld-On™55,Weld-On™42,
Scotch-Weld™DP-100,Durabond™105CL,LightCure
3104,LightCure3105,UltraLight-Weld™3072,or
PlasticWelderII.
–ForbondingsheetofSpectartosheetofacrylic,use
Weld-On™42,Durabond™105CL,LightCure3104,Light
Cure3105,UltraLight-Weld™3094,UltraLight-Weld™
3072,orPlasticWelderII.
–ForbondingSpectarsheettopolycarbonatesheet,use
Weld-On™58,Weld-On™55,Durabond™105CL,Light
Cure3104,LightCure3105,UltraLight-Weld™3094,
UltraLight-Weld™3072,orPlasticWelderII.
•Usethefollowingprocedure
–Startwithaflatsurface.
–Preparethesheetproperly
•Removeallforeignparticles.
•Wipesurfacewitha50:50mixtureofisopropyl
alcoholandwater.
•Allowsurfacestodrythoroughlybeforebonding.
•Sandingwithfine-gritsandpapertolightlyroughen
thesurfacestobebondedmayimprovebond
strength.
-Applythetwo-componentsystemtoonesurface.
-Placethetwosurfacesindesiredbondedposition.
-Filljointscompletelywithadhesivesothatnovoids
remain.
-Useajigorfixturetosecurelyholdpartsbeing
bondedtogetherwhilecuring.
-Followmanufacturer’srecommendationsforproper
pressureandtimeneededfortheadhesivetocure.
-Alwaysuseproperventilation.
Mechanical fasteningBecauseofitsoutstandingtoughness,sheetofEastman
Spectar™copolyesteradaptstomechanicalfasteningmore
readilythansomeothermaterials.Thismethodisuseful
whenassemblingorinstallinglargeorheavyparts,or
whenasuitablesolventoradhesivesystemisnotavailable.
Usescrewsdesignedspecificallyforplastics.Ifbolting
partstogether,allowforthermalexpansionand
contractionbydrillingoversizedholes.Makesurethe
holeshavesmoothedges.Useofwashersissuggested
whenboltingforbetterloaddistribution.
Usemetalinsertsiffrequentassembly/reassemblyis
involved.Insertsarenotrecommendedwherethermal
expansionandcontractionmayoccur.
Donotoverlytightenscrewsoruseself-tappingscrews.
Plastic weldingAlwayspredrilltheopeningfortherivetlargeenoughto
allowforexpansionandcontractionoftheplasticsheet.
Useofmetalrivetsisnotrecommendedwhenmechanically
fasteninganyplasticsheet,butifitisnecessarytouse
metalrivetstofastenEastmanSpectar™copolyester,use
rivetsthatarespecificallydesignedforplastics.They
shouldhavelargefasteningheadstodistributethestress
loadonthe“rivethead”side.Also,theuseofawasher
onthe“nonrivethead”sideisrequiredtodistributethe
stressloadthatwillbeinducedwhenusingtightening
metalrivets.Whenusingplasticrivets,alsoallowfor
expansionandcontractionofthesheet.Plasticrivetsare
recommended.
Technologyhasbeendevelopedthatallowsplasticsheet
fabricatorstoobtainclear,strongbondsbyweldingwitha
rodofSpectarsheetmaterial.Thetechnologycanbeused
tobondSpectarsheettoitselfortootherplasticsheet
materials.
Likemetalwelding,particularlywire-feedwelding,plastic
extrusionweldingproducesastrong,uniformbondon
plasticsheetorotherplasticapplications.
10
Therearemanyadvantagesofplasticweldingthatcan
beeasilyrealizedwhenworkingwithSpectarsheet.
Advantagesinclude
•Nomessyorenvironmentallyunsafegluesorsolvents
•Clear,yettoughbonds
•Quickfabrication—nodryingtimerequired
•Watertight,long-lastingjoints
•Diversefasteningmethodforavarietyofapplications
•Better,strongerdesigns
•Suppliersofcopolyesterrods
–K-MacPlastics
3821ClayAvenue,SW
Wyoming,MI49548
Tel:(616)406-0671
www.k-mac-plastics.com
–NewImagePlastics
2411S.LocustStreet
CanalFulton,OH44614
Tel:(330)854-3010
www.plasticweldingrod.com
Tips for bondingThebondingrecommendationsoutlinedherearebasedon
experienceworkingwithEastmanSpectar™copolyesterin
Eastman’sTechnicalServicelaboratoriesinKingsport,
Tennessee.Theycanbeusedasastartingpointoras
guidelinesindeterminingoptimumbondingconditions.
•Startwithaclean,flatsurface.
•Preparethesheetproperly.Removeallforeign
particles.
–Wipesurfacewitha50:50mixtureofisopropyl
alcoholandwater.
–Allowtodrythoroughlybeforebonding.
Bonding sheet of Spectar™ copolyester to itself•Useanappropriatesolventoradhesive.
–Usesolventssuchasmethylenechloride,
cyclohexanone,tetrahydrofuran,Weld-On™3,
Weld-On™4,CasewaySC125,MC-Bond,oratwo-
componentadhesivesuchasWeld-On™58.
Using solvents•Besurethatsurfacestobebondedaresmoothandmate
well.Edgebondsshouldbefinishedusingajointeror
router.
•Applysolventtothejointedgewithahollowneedle.
Solventwillwickintothejointbycapillaryaction.
•Useminimumamountofsolventtowetsurfacesto
bebonded.
•Useajigtoholdpartsinplacepriortobonding.
•Greentimeistypically60–90sec.
Using a two-component adhesive system•Applythetwo-componentsystemtoonesurface.
•Uselightpressuretoholdthesurfacesbeing
bondedtogether.
•Followmanufacturers’instructionsfordetails.
Bonding sheet of Spectar™ copolyester to other materials such as acrylic or polycarbonate•Useanadhesivesystemratherthanasolvent-based
system.
•UseWeld-On™58orWeld-On™42.
•Whenusingadhesives,sandingwithfine-gritsandpaper
tolightlyroughenthesurfacestobebondedmay
improvebondstrength.
•Applythetwo-componentsystemtoonesurface.
•Followmanufacturers’recommendationsfortheproper
pressureandtimeneededfortheadhesivetocure.
•Eastmanhasfoundthaturethane-basedadhesives
workbest.
•Donotusetoomuchsolventorallowsolventtopoolon
theplastic.
•Donotusemethylethylketone,cyclohexanone,orTHF
foredgebonds.
11
Problem Possible cause Possible remedies
Poorbondappearance
VoidsduetoroughsurfacesNeedsmootheredges.Startwithjointededges.Addrouteredge.
Whiteningduetosolventinducedcrystallization
Minimizeamountofsolventused(avoidsolventpooling).Tryusing“dip”method.Switchtoadhesives.
Whitening/bubblesduetohighhumidity
Fabricateinanareawithlowrelativehumidity.Usesolventswithaslowerevaporationrate.
PartsmovedbeforebondsetsUseajig,clamp,orfixturetoholdthepartsfixeduntilthebondhassetup.
Solventbondstrength
Wrongsolvents Userecommendedsolvent.
ExcessivesurfaceroughnessStartwithajointed/routededge.Ifnecessary,addmethylenechloridetosolventmixturetohelpdissolveroughness.
AAMManufacturingInc.1755HubbardDriveBatavia,IL60510Tel: (800)272-0595Fax:(630)406-9622
IPSCorporation455W.VictoriaStreetCompton,CA90220Tel:(310)898-3300
Polysciences,Inc.400ValleyRoadWarrington,PA18976Tel:(800)523-2575
For additional information on the adhesives and solvents discussed, contact
FormingForming methodsSheetofEastmanSpectar™copolyesterisuniquelysuited
toavarietyofformingoperations,offeringacombination
offeaturesunmatchedbyacrylicorpolycarbonate.The
sheetcanbeformedwithoutpredrying,formsatlower
temperatures,heatsandcoolsrapidly,releaseseasilyfrom
themold,andprocesseswithimpressiveconsistency,all
translatingintomajorlabor,energy,andcapitalsavings.
Deepdrawsandintricatepartdefinitionareroutine,using
simplevacuumpressure.Themostcommonthermoforming
techniquesincludelinebending,freeforming,and
vacuumforming.
Thermoforming ovenSheetofEastmanSpectar™copolyestermaybeheated
usingsingle-ordouble-sidedradiantheatorconvection
ovens.Whilesingle-sideheatingiscommon,itcanheat
thesheetunevenly.However,Spectarsheetwillformwell
usingone-sidedheatatgauges≤0.177mil.Formorecritical
applicationssuchasdistortionscreen-printing,complex
shapes,orverydeepdraws,usedouble-sidedradiantheat
withzonecontrolifpossible.
Vacuum formingLinebendingandfreeforminglimitthevarietyofshapes
thatcanbeproducedfromsheetofEastmanSpectar™
copolyester.Thereis,however,virtuallynolimittothe
varietyofshapesthatcanbeachievedthroughvacuum
forming.Inthisprocess,heatthesheetandthenposition
overamaleorfemalemold.Evacuatetheairbetweenthe
sheetandthemoldsurface.Holdthevacuumwhilethe
partcools,thenreleasethevacuumandremovethepart
fromthemold.Positivepressure,oracombinationof
positiveandnegativepressure,canbeused.Spectarsheet
canbethermoformedonvirtuallyanyhorizontal
thermoformingequipment.
12
Troubleshooting guide for bonding sheet of Eastman Spectar™ copolyester
Free formingFreeformingisagoodtechniquetoproducedomes,
bubbles,andothersymmetricalshapes.Achievingsome
shapesmaybeassimpleasallowingthesheettosaginthe
oven,withoutpressure,toadesireddepth,atwhichpoint
thepartisremovedtocool.Heatthesheet,thenseal
againsttheopeningofapressureboxandapplyair
pressuretoforcethesheetintothedesiredshape.Hold
pressureconstantwhilethepartcools.Theshapeofthe
openingandthequantityofairforcedintothebox
determinetheshape.Ineithercase,theformedpart
exhibitsanexcellentfinishbecausetheheatedsheet
nevermakescontactwithamoldsurface.Anotheroption
involvesusingavacuumboxthatgivessimilarresults.
Air inAir out
Hold pressure constantwhile the part cools.
Line bendingTolinebend,heatthesheetononesideto100°to120°C
(212°to250°F)alongastraightline.Bendtothedesired
angleandholdinplaceuntiltheparthascooledandthe
newshapeisset.Ajigisusefulforholdingthepartinplace
duringcooling,althoughitmaybepossibletoholdthepart
inthedesiredpositionbyhand.
Cold bendingColdbendingcanbeusedtoproducesimpleshapes
fromsheetofEastmanSpectar™copolyester.When
brakeforming,themaximumamountofbendwilldepend
onsheetthicknessandrateofdeflection.Coldbending
sheetmorethan2.5-mm(0.100-in.)thickwilllikelycause
highstresslevels,whichmayleadtopartfailure.When
coldbending,usethegeneralrecommendationof
radiusequals100Xthicknessofsheet.
Forming temperatureSheetofEastmanSpectar™copolyesterwillformatlower
temperaturesandoverawiderrangeoftemperaturesthan
acrylicorpolycarbonate.Typicaloventemperaturesof
200°to260°C(400°to500°F)producecorresponding
sheettemperaturesof135°to155°C(275°to310°F),
measuredfromthetopofthesheet(intopheatonly
oven).Toomuchheatcanresultinexcessivesag,which
mayleadtowebbingorbridgingwhenvacuumisapplied.
Monitorsheettemperatureswithaninfraredthermometer
orobservethedegreeofsag.Ifthesheethasbeenstored
forlongperiodsunderconditionsofhighhumidity,selecta
formingtemperatureonthelowerendoftherange.
Ageneralguidetoformingtemperaturefollows.
Factor Temperature range
Deepdraws Higherend
Moderatedraws Lowerend
Largeparts Lowerend
Highmoisture Lowerend
Complexdetail Higherend
Part removalReducethepossibilityofwarpingbyallowingformedparts
tocoolto50°C(120°F)orlowerbeforeremovingthem
fromthemold.Theywillcontinuetocoolafterremoval,
sopropersupportisrequiredtopreventdeformation.This
isespeciallytrueforlarge,heavyparts.Topreventdishing
(concaveshape),largepartsshouldbesupportedalong
theiredges,facedown,untilcompletelycooled.Donot
nestformedpartssincethiscancauseblockingand
scratching.Largepartsshouldbefullysupportedwhen
beingtransportedtopreventexcessiveflexing.
13
MoldsMold materials
Commonlyusedmoldmaterialsincludewood,vacuum
board(mediumdensityfiberboard),pressurelaminates
(forflatsurfaces),plasters,aluminum-filledepoxies,
automobilebodyputties,fiberglass,andaluminum.Molds
madefromwoodorvacuumboardareinexpensiveand
easytofabricateintothedesiredshapewithcommon
woodworkingtools.Limitationsofwoodenmoldsinclude
durability,slowerpartcooling,andlesscontrolover
surfacetexture.
Mold finish
FormedsheetofEastmanSpectar™copolyesterprovides
anexcellentreproductionofthemoldsurface.Forthis
reason,vacuumholesshouldbenomorethan0.4mm
(0.015in.)indiameter.Keepthemoldsurfacecleanduring
formingoperation(evendustmarkscanbepickedupinthe
surfaceoftheformedpart).Asmooth,cleanmoldsurface
producesasmooth,cleanformedpart.Ontheotherhand,
usinguniquemoldfinishesoffersawiderangeof
customizeddesignpossibilities.
Mold design
FormedsheetofEastmanSpectar™copolyestertypically
hasverygoodreleasecharacteristics.Formostmalemolds,
aminimumdraftangleof5to7degreesensureseasypart
removal.Large-scaleproductionrunsmayjustifythe
productionofaprototypemoldtodetermineoptimum
draftangles,shrinkage,andothermolddesignfeatures.
PartsformedfromSpectarsheetwilltypicallyshrink
about0.5%.
Sharpedgesandcornersonmoldsshouldbeavoided.A
minimuminternalcornerradiusequaltotheinitialsheet
thicknessisrequired.AlthoughformedsheetofSpectar
typicallyhasverygoodreleasecharacteristics,the
complexityofthemoldhasasignificanteffect.
Thickness control
Thewallthicknessofvacuum-formedpartsvarieswith
thinnerareasoccurringatthepointsofdeepestdrawor
greateststretch.Forexample,ifapanconfigurationis
drawnintoafemalemold,thethinnerareaswilloccur
atthecorners,orface,oftheformedpart.Material
distributioncanbeoptimizedthroughmolddesign,the
useofplugassist,orbillowing,dependingonthespecific
designofthepart.
Predecorated sheetSinceitformsatlowertemperatures,sheetofEastman
Spectar™copolyestermaybeusedwithlessconcernabout
overheatingpreappliedinksorvinylfilms.Insomecases,
partshavebeenformedwiththedecoratedsurfacein
contactwiththemoldwithnoadverseeffects.The
compatibilityofSpectarsheetwithvinylcanallowthicker
gaugesheettobeusedthanwithpolycarbonatewithout
thefearofdamagingthevinyl.Thesefactorsmake
predecorationandsubsequentformingasnap!Another
factorinpredecoratingSpectarsheetisitsevenmaterial
distributionduringtheformingprocess,leavinglesschance
forink,paint,orvinylthinning.
14
Problem Possible cause Possible solution
Webbingorbridging
Sheettoohot Decreaseheatingtimeortemperature.
ComplexshapeUsefemalemoldand/orprestretchsheetwithplugorpressureassist.
Bubblesinformedsheet Sheettoohot Reduceformingtemperature.
Surfacedefectsonpart
Oversizedvacuumholes Usesmallerholes.
RoughmoldsurfaceSand/polishmold.
Usealuminummold.
Dirtymold Cleanmold.
Releasedifficulties Insufficientdraft Increasedraftangleorusefemalemold.
PoormaterialdistributionFormingtechnique Tryplug,bubble,orvacuumassist.
Unevenheat Adjustheatzones.
Unevensag Unevenheat Adjustheatzones.
Poordetail
Vacuumreleasedtoosoon Holdvacuumlonger.
Vacuumappliedtooslowly Applyvacuumsooner.
Sheettoocold Increaseheatingtimeortemperature.
Warpedparts Insufficientcooling Allowpartstocoollongerinmold.
Tips for thermoformingEastman’sthermoformingrecommendationsarebasedon
experienceworkingwithsheetofEastmanSpectar™copolyester
initsTechnicalServicelaboratoriesinKingsport,Tennessee.
Theycanbeusedasastartingpointorasguidelinesin
determiningoptimumsheetthermoformingconditions.
•Useaminimumdraftangleof5°inmalemoldsforeasy
partrelease.
•Keepmoldsveryclean.Removedustwithadampclothand
blowitoffwithpressurizedair.
•Useloweroventemperatures(200°–250°C[400°–480°F])
thanusedforacrylicandpolycarbonate.
•Usealowermoldtemperaturethanusedforacrylicor
polycarbonate.Forlong-termproduction,atemperature-
controlledmoldisrecommendedbutnotrequired.
•Heatthesheetto135°–155°C(275°–310°F).The
optimumis150°C(300°F)usingatopheaterovenand
measuredfromtopofsheet.Applyheatonthesidethat
willbeoutsidethebend.
–Highertemperaturesfordeep-drawnpartsand
highdetail
–Lowertemperaturesforlargepartsandshallowdraws
•Useamountofsagasasheet-heatingcontrol.
•Useavacuumof508mm(20in.)Hgorgreater.
•Removethepartatlowertemperatures(50°C[<120°F])
topreventpartwarpage.Whenusingamalemold,the
partshouldberemovedassoonaspossibleandthen
placedbackontothemold.Thishelpspreventthepart
fromstickingtothemoldandhelpspreventpartwarpage
asitcontinuestocool.
•Forhighlydetailedmolds,alightdustingwithtalcum
powderhelpstheparttoreleasemoreeasilyandwill
extendthelifeofthemoldaswell.
•Alwaysallowgenerousradiioninternalcorners(≥initial
sheetthickness).
•Donotdrythesheetbeforethermoforming—not
necessary.
•Donotusetoocoldamold(25°C[<60°F])toprevent
nonuniformstretchingandpartwarpage.
•Donotusetoohotamold(60°C[>122°F])toprevent
warpingorsticking.
•Donotoverheatthesheet(165°C[>330°F])toprevent
excessivesagging.
15
Troubleshooting guide for thermoforming sheet of Eastman Spectar™ copolyester
DecoratingThereareliterallyhundredsofcommerciallyavailableinks
andpaintsthatcanbeusedtodecoratesheetextruded
fromEastmanSpectar™copolyester.Whenchoosinginkor
paint,considerationshouldbegiventothefitness-for-use
requirementsofdecoratedparts.Forexample,willthe
decoratedpartbesubjectedtoconsumerabuseorwillit
encounterlittleornoabuse,suchasadecoratedsign.The
followinginformationofferssomegeneralguidance
regardingthedecorationofSpectarsheet.
General informationWhetheryouwanttoscreen-print,spraypaint,oruseany
othermethodtodecorateafabricatedsheetofEastman
Spectar™copolyester,thecorrectinkorpaintformulation
mustbechosenthatallowsthefullydecoratedpartto
meetitsintendedfitness-for-userequirements.Sheet
extrudedfromSpectarinherentlyexhibitsexcellent
chemicalresistance.Goodchemicalresistanceisgenerally
consideredadesiredcharacteristic;however,itisalsoone
ofthereasonsthatinkorpaintadhesiontothesurfacecan
sometimesbemarginal.Theproperchoiceofsolvent,in
combinationwiththeresinbackboneoftheinkorpaint,is
animportantconcernandshouldbeevaluatedbytheink
manufacturerusingtheScotch™tapeadhesionmethod.
Anotherinherentpropertyofthesheetisitstoughness.
Thispropertycanbecompromisedbyimproperly
decoratingthesheet.Thewrongsolventsystemand/ora
rigidfilm-forminginkorpaintsystemcannegatively
affectthetoughnessofthedecoratedpart.
Followingtheserecommendations,alertingyourink
suppliertotheseconcerns,andknowingthefitness-for-use
requirementsofthefullydecoratedpartwillminimize
theseconcerns.
CleaningBeforeanypieceofplasticcanbedecorated,itneedstobe
cleanedandstaticbuildupremoved.Thisiseasilydoneto
sheetofEastmanSpectar™copolyesterusinga50:50
mixtureofisopropylalcoholandwater.Aswithpaintsor
inks,therearemanycommercialsolutionsthatcanbeused
tocleanandremovestaticfromplasticsheet.Itshould
notbeassumedthatthesesolutionscanbeusedon
Spectarsheet.Eastmanencouragestheuseofthese
mixturesONLYaftertestinginaninconspicuousarea.
Applythecommercialmixtureaccordingtothe
manufacturer’sinstructionsandinspecttheareafor
visualcrazingand/orhazingofthesheetsurface.
Printing inks and substratesThermoplasticsubstratesareimpervious,ornonporous,
andnormallyrequirespecificinkformulationsforquicker
dryingandbetteradhesion.Solvent-andwater-basedinks,
aswellasultravioletandelectron-beamcurableinks,are
availableformostplasticprintingprocesses.Enamel,
epoxy,acrylic,polyester,andpolyurethane-basedinks
arecommonlyusedforpolymers.
Surface tensionsForbetterwetting,thesurfacetensionsoftheinks
shouldbelowerthanthatoftheplasticsbeingprinted.
Water-basedinkstypicallyhavehighersurfacetensions
thansolvent-basedinks.Water-basedinkscanbeadjusted
withalcoholtolowertheirsurfacetensionforimproved
wettingandadhesion.Workwithexperiencedink
suppliers—itiseasiertoadjusttheinkthanthesubstrate.
CoronasurfacetreatmentscanbeappliedtoEastman
Spectar™copolyester.Thetreatmentincreasessurface
tensionandsurfacepolarityresultinginimproved
adhesion.
Static controlStaticcontrolisanimportantissuewhenprintingon
thermoplasticsubstrates.Excessstaticmaycauseblocking
insheetfedoperations.Inconsistentinklaydownininkjet,
laser,andsimilarprintingtechniquesmayalsobe
attributedtostaticcharge.Groundingtheequipment
andsubstrate,usingstaticeliminatorbars,andforced
deionizedairblownontothesubstratehaveprovento
alleviatetheseproblems.
16
Choosing inks or paintsBeforechoosinganink/painting/decorationtechnique,
theend-userequirementsneedtobewellunderstood
andconveyedtotheprinter,inkmanufacturer,paint
formulator,etc.Manycommerciallyavailableinksand
paintscanbeusedtodecoratesheetofEastmanSpectar™
copolyester.Thesolventschosentoformulatemostinksor
paintsdonotdecreasethephysicalpropertiesofthesheet.
Generally,thechosenresinintheinkorpaintformulation
willcompromisethephysicalpropertiesofthesheettoa
greaterextentthanthesolventsintheformulation.There
arealwaysadhesionconcernswithanyinkorpaintafter
thecoatingisappliedtoaplasticsubstrate.Itisextremely
importantthatadhesionbetestedafterthechosenink
orpainthasbeenappliedAND is fully cured!Eastman
recommendstestingforadhesionafterthesamplescan
bephysicallyhandledandhavebeencuredinanovenfor
48hoursat50°C.UsuallytheScotch™tapeadhesiontestis
performed(ASTMD3359-B).Thisisdonebyetchinga
“checkerboard”patternonthedecoratedsheetand
attemptingtoremovethepaintorinkintheetchedarea
withtape.ThetestcallsforScotch™610tapetobeused
andabrisk,steadypullshouldbeperformed.Thedriedink
orpaintfilmshouldbehardtoremovebythismethod.
WorkatEastmanhasshownthatthe“flexibility”ofthe
driedfilm,whetheritisinkorpaint,isanimportant
characteristicforadhesionandretentionofsheettoughness.
Driedinkorpaintfilmsthatremainflexibleathighandlow
temperaturesseemtoadherebettertothesheetandhelp
maintainsheettoughnessbetterthan“rigid”film-forming
inkorpaintsystems.Thisisonlyimportantifthefitness-
for-userequirementsofthedecoratedsheetrequirethe
decoratedparttobesubjectedtoabuseorroughhandling.
Arigidfilm-forminginksystem,whenappliedtoSpectar
sheet,shouldbeexpectedtobehaveinamorebrittle
mannerthanaflexiblefilm-forminginksystem.Ifthefully
decoratedfitness-for-usesheetofEastmanSpectar™
copolyesterisapoint-of-purchasedisplaywhereimpact
isn’tamajorconcern,mostanyinkwillmeettheneedsof
thisapplication.Inthiscase,adhesiontoSpectarsheetwill
betheonlyconsideration.
Testing ink or paint•Coatorprintsamplesofthechoseninkorpaintonsheet
ofEastmanSpectar™copolyester.(Includeafloodcoat
ifnecessary.)
•Cureordrythepreparedsamplespertheink
manufacturer’srecommendations.
•Checkadhesion(ASTMD3359-B)beforeandafteraging
inanovenat50°C(122°F)for48hours.
•Checktheimpactofagedsamplesatroomtemperature
and210°C(410°F)usingASTMD3763.
Spray paintingConventionalspray-paintingtechniquesareoftenusedto
decoratelargepanels.Therearecommercialspraypaints
availableforsheetofEastmanSpectar™copolyester.
Whenselectingpaint,carefullyconsiderfitness-for-use
requirementssuchasdryfilmadhesionandimpact
strengthretention.Obtainmoredetailedinformation
aboutthesecharacteristicsfromthepaintsupplier.
Dry film adhesionSheetofEastmanSpectar™copolyestergenerallyexhibits
excellentchemicalresistancecomparedwithotherplastic
sheetmaterials.Asaresult,somesolvent-basedpaints
designedforusewithpolycarbonateoracrylicmaynotbe
sufficientlyactivetoprovidegoodadhesiontoSpectar
sheet.Generally,paintthatproducesaflexible,toughdry
film,suchassomepolyurethanes,hasbetteradhesionthan
oneyieldingarigid,brittlefilm.Contactyourpaintsupplier
fordetails.
Impact strengthTheexcellentimpactstrengthofsheetofEastman
Spectar™copolyesteraccountsforitsuseinahostof
demandingapplications.Itisimportantthatsuch
fitness-for-userequirementsbeclearlycommunicatedto
thepaintsupplier.Contactyourinkorpaintsuppliersfor
recommendationsonwhattousewithPETG.
17
Spray maskingConventionalspray-maskingmaterialsworkwellwith
sheetofEastmanSpectar™copolyester.Comparedwith
acrylicorpolycarbonate,itmaybeeasiertocutawaythe
maskingsincepartsformedfromSpectarsheetusually
exhibitcrisperformingdetailtoguidetheknife.When
cuttingthemasking,useasharpknifeandminimum
pressuretoavoidcuttingintotheplasticsheet,asthis
maynotchthesheet,reducingitsimpactresistance.
PrintingManyprintingprocessescanbeusedwithsheetof
EastmanSpectar™copolyester.Theprocessdepends
largelyontheconfiguration,productionvolume,and
fitness-for-userequirementsofthefinishedpart.Specially
formulatedinksareavailabletomeetthespecific
requirementsforagivenenduse.Consultyourinksupplier
todeterminethebestchoiceofinksandapplication
techniques.
Hot stampingCopy,trademarks,andotherdesignelementsmaybe
transferredtoflat,smoothsurfacesonsheetofEastman
Spectar™copolyesterbyhotstamping.Eastmanhasfound
dietemperaturesof149°to204°C(300°to400°F)anda
1to2seconddwelltimeat0.62MPa(90psi)agood
startingplace.Additionalinformationonhotstamping
canbeobtainedfromfoilmanufacturers.
Vinyl decoratingBenefitsofvinyldecoratingsheetofEastmanSpectar™
copolyesterincludeuniformcolordistributionandcorrect
colormatches.Also,vinylcanbeappliedtofirstand
secondsurfacespriortoforming.
Summary of fabricating and forming Eastman’srecommendationsarebasedonexperience
workingwithsheetofEastmanSpectar™copolyester.
Sheet storage and handling•Storesheetatroomtemperatureinadryarea,not
directlyexposedtosunlightorheat.
•Makecertainthemaskingfilmisnotremovedpriorto
use,asnormaldustanddirtwillbeattractedtothe
sheetbecauseofstaticelectricity.Themaskingwill
alsopreventscuffingandscratching.
•Topreventwarpage,thesheetshouldideallybestored
flat,asdelivered.Ifverticalstorageisnecessary,itisbest
tostoreataslightanglewithsupportunderneath.
Fabricating•Mosttoolssuitedforplasticsarebest,buttoolsfor
woodormetalmaybeused.
•Cold bending—Coldbrakebendingcanbeusedto
producesimpleshapes.Themostattractivebendsare
obtainedwith thicknesses less than 3.0 mm (l in.).The
radiusofcoldbendsshouldbenolessthan100times
theinitialsheetthickness.
•Hot bending—Anelectricstripheaterwithoptimum
sheettemperatureof107°C(225°F)maybeused.
•Sawing—Circular,bandandsabersaws,jigsaws,and
handsawsaresuitable.Triple-chipbladesofferthebest
performanceforcircularsaws.
•Drilling—Drillbitsdesignedforplasticsaresuggested.
•Shearing—Canbecutusingasheetmetalshearwith
sharpblades.Typically,shearcuttinglessthan16.5-mm
(l-in.)gaugeyieldsthebestvisualresults.Qualityof
theshearededgedependsontheshearingmachine’s
tolerances,cuttingcapacity,andblade“rake”angle.
18
Apply heat gradually using a gentle sweeping motion.
•Punching—Canbepunchcutwithbestvisualresults
at gauges less than l in. (3.0 mm).Qualitydependson
thepunchingmachine’stolerances,cuttingcapacity,and
blade“rake”angle.
•Routing—Toobtainthebestroutingresults,usetwo-
flutetwistedcutters.
•Common heat guncanbeusedtoeliminatescratches.
Caremustbetakentoavoidwarping.Practiceon
noncriticalareasfirst.Lightsurfacescratchescaneasily
beremovedfromsheetofEastmanSpectar™copolyester
byapplyingheatfromahand-heldtorch(typicallybutane
oroxygen/hydrogen)oranelectricheatgun.Toremove
shallowscratches,itisbesttoapplyheatevenlywith
severalpasseslengthwiseoverthescratch.Toavoid
overheatingordamagingthesheet,careshouldbetaken
tonotfocustheheatinaconstantposition.Thoughthis
techniqueworksforlightsurfacescratches,deep
scratchesorgougesinthematerial’ssurfacearenot
suitableforrepairbythismethod.
•SheetofEastmanSpectar™copolyestermaybe
–Mechanical polished—Edgefinishingusing
mechanicalpolishers1isbestdonebystartingwithas
flatanedgeaspossible(suchasfromjointingorrouting
aftersawing—sawededgesaredifficulttofinish
becauseoftheroughness)andthenusingfairlylight
pressureonthepartandaconstantfeedrateacross
thepolishingsurface.
–Flame polished—Forbestresults,usea cooler
flame (butane or propane)afterthesawededgehas
beendeburred,jointed,routed,and/ordiamondedge
polished.Polishingisbestwhenusingauniformrateof
movementandisverytechniquedependent.Flame
treatmentcanembrittlethesheetedge.
–Solvent polished—Usemethylethylketone(MEK)or
methylenechloride.Avoidspilloverandpoortechnique.
ThisismoredifficultwithsheetofEastmanSpectar™
copolyesterthanwithacrylicsheet.
–Hot stamping and heat transfer printingaregood
decoratingmethods.Variousfoilsandtransferdecals
havebeenusedsuccessfully.
Thermoforming•No need to drythesheetbeforethermoforming.
•Readilyformablebyconventionaltechniques,including
traditionalvacuumforming,bending(coldorhot),anda
varietyofplug-assist,pressure,bubble,andsnap-back
methods.
–Uselower oven temperatures 200°–260°C
(400°–500°F)thanusedforPMMAandPC.
–Uselower mold temperatures <50°C(<120°F)than
usedforPMMAandPC.
–Sheettemperaturesof135°–155°C(275°–310°F)are
recommendedwithanoptimumtemperaturebeing
150°C(300°F).
–Useplug-assistmethodsfordeep-drawmolds.
•Useamoderatedraftangle(>3°–5°)onmoldstoaid
releaseofthefinalpart.
–Removethepartatlowertemperatures(lessthan65°C
[150°F])topreventpartwarpage.
Bonding•Solvent—Forsolventbondsthatareclear,long-lasting,
strong,tough,andbubble-free,usecommercialproducts
suchasCasewaySC125,MC-Bond,andWeld-On™3
and4.
•Don’t usetheregularsolventsystemsdesignedfor
polycarbonateoracrylic.
• Adhesives—Startwithaflatsurface.Foradhesive
bonding,preparethesheetproperly
–Lightlysandwithfine-gritsandpapertoimprove
adhesion.
–Wipethesurfacewitha50:50mixtureofisopropyl
alcoholandwater.
–Allowtodrythoroughlybeforebonding.
–SuggestedadhesivesincludeWeld-On™40,
Weld-On™42,andWeld-On™58.
1Diamond polishers are available from Mutronic (Tel: [0049] 8362/930900) or Edge Finisher Corp. (Tel: [1] 203-796-7923).
19
Decorating sheet of Eastman Spectar™ copolyester•Spray painting—Whenselectingpaint,carefullyconsider
fitness-for-userequirementssuchasdryfilmadhesion
andimpactstrengthretention.Obtainmoredetailed
informationaboutthesecharacteristicsfromthepaint
supplier.
• Dry film adhesion—Avoidsolvent-basedpaints
designedforusewithpolycarbonateoracrylic.Generally,
apaintthatproducesaflexible,tough,dryfilmhasbetter
adhesionthanoneyieldingrigid,brittlefilm.Contactyour
paintsupplierfordetails.
• Spray masking—Conventionalspray-maskingmaterials
workwellwithsheetofEastmanSpectar™copolyester.
Whencuttingthemasking,useasharpknifeand
minimumpressuretoavoidcuttingintotheplastic
sheet,asthismaynotchthesheet,reducingitsimpact
resistance.
• Printing—Manyprintingprocessescanbeusedwith
sheetofEastmanSpectar™copolyester.Theprocess
dependslargelyontheconfiguration,productionvolume,
andfitness-for-userequirementsofthefinishedpart.
Speciallyformulatedinksareavailabletomeetthe
specificrequirementsforagivenenduse.Consultyour
inksuppliertodeterminethebestchoiceofinksand
applicationtechniques.
• Vinyl decorating—Benefitsofvinyldecoratingsheet
ofEastmanSpectar™copolyesterincludeuniformcolor
distributionandcorrectcolormatches.Also,vinylcanbe
appliedtothefirstandsecondsurfacespriortoforming.
20
Eastman Chemical CompanyCorporate HeadquartersP.O. Box 431Kingsport, TN 37662-5280 U.S.A.
Telephone:U.S.A. and Canada, 800-EASTMAN (800-327-8626)Other Locations, (1) 423-229-2000Fax: (1) 423-229-1193
Eastman Chemical Latin America9155 South Dadeland Blvd.Suite 1116Miami, FL 33156 U.S.A.
Telephone: (1) 305-671-2800Fax: (1) 305-671-2805
Eastman Chemical B.V.Fascinatio Boulevard 602-6142909 VA Capelle aan den IJsselThe Netherlands
Telephone: (31) 10 2402 111Fax: (31) 10 2402 100
Eastman (Shanghai) Chemical Commercial Company, Ltd. Jingan Branch1206, CITIC SquareNo. 1168 Nanjing Road (W)Shanghai 200041, P.R. China
Telephone: (86) 21 6120-8700Fax: (86) 21 5213-5255
Eastman Chemical Japan Ltd.MetLife Aoyama Building 5F2-11-16 Minami AoyamaMinato-ku, Tokyo 107-0062 Japan
Telephone: (81) 3-3475-9510Fax: (81) 3-3475-9515
Eastman Chemical Asia Pacific Pte. Ltd.#05-04 Winsland House3 Killiney RoadSingapore 239519
Telephone: (65) 6831-3100Fax: (65) 6732-4930
www.eastman.com
Material Safety Data Sheets providing safety precautions
that should be observed when handling and storing Eastman
products are available online or by request. You should obtain
and review the available material safety information before
handling any of these products. If any materials mentioned
are not Eastman products, appropriate industrial hygiene and
other safety precautions recommended by their manufacturers
should be observed.
Neither Eastman Chemical Company nor its marketing affiliates
shall be responsible for the use of this information or of any
product, method, or apparatus mentioned, and you must make
your own determination of its suitability and completeness for
your own use, for the protection of the environment, and for the
health and safety of your employees and purchasers of your
products. NO WARRANTY IS MADE OF THE MERCHANTABILITY
OR FITNESS OF ANY PRODUCT, AND NOTHING HEREIN WAIVES
ANY OF THE SELLER’S CONDITIONS OF SALE.
Eastman and Spectar are trademarks of
Eastman Chemical Company.
All other brands are the property of their respective owners.
© Eastman Chemical Company, 2011.
TRS-236A 5/11Printed in U.S.A.