Crack formation in twin-sheet thermoformed HDPE kayaks

Thermoforming is an industrial manufacturing method to form plastic sheets into shapes such as small boats. Our industrial partner uses twin-sheet thermoforming which includes joining two sheets of high density polyethylene (HDPE) to manufacture small boats. Cracking adjacent to the welded area has been observed in one of their joint designs. The cracking problem appears every 2-3 years and its origin is currently unknown. The objective of this study is to identify the source of this cracking problem and propose a practical solution. Since there are no published scientific studies providing data for twin-sheet thermoforming, our work will provide published fundamental data about this process. In order to achieve these goals, materials analysis, modeling and process evaluation will be performed. We expect to find the source of the cracking in the characteristics of the plastic, working conditions and the joint design.

Faculty Supervisor:

Paula Wood-Adams

Student:

Partner:

Pelican International Inc

Discipline:

Engineering

Sector:

Manufacturing

University:

Concordia University

Program: