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A billow holds a 0.64 wall ratio at a 0.9 draw where plain vacuum gives 0.42, and the gap widens as the draw deepens. It costs about four seconds of cycle time, which is the entire price.
A co-extruded seal strip does two jobs with two materials: the soft leg gives 12 N per 100 mm at 30 percent deflection and the rigid leg holds it in the groove. Compression set, not hardness, is what ends the seal.
Time to failure falls from 2000 hours to 12 as stress goes from 20 percent of yield to 60, so each ten points costs half a decade. PE survives 3.5 percent strain in the same solvent where PC fails at 0.4.
Undispersed filler falls from 18 percent to 2.2 over six passes, and almost all of that happens in the first three. Mooney viscosity keeps falling the whole time, from 60 to 39, which is the part nobody budgets for.
A match mould holds a 0.76 wall ratio at a 1.5 draw where vacuum gives 0.31, and it holds both surfaces. It also needs 600 kN of clamp on a one square metre part, and that is what the machine has to deliver.
Gloss climbs from 22 to 58 units as the melt goes from 180 C to 220 C and then stops. Roughness falls from 2.8 to 1.2 micrometres as die land goes from 8 to 24 mm. Neither fixes the joint, which is a movement problem.
Mark severity is a U, not a slope: 6.5 at 60 C, 2.0 at 90 C, 9.0 at 120 C. The other lever is pin area, where the same 3 kN leaves a 60 micrometre mark on a 2 mm pin and 11 on a 10 mm one.
Coat weight sets the line speed: 120 m/min at 5 g/m2, 18 m/min at 50. Corona dose sets the adhesion, and it stops paying at about 20 W min/m2, where peel reaches 3.2 N/25 mm and the next 60 units add half a newton.
Blow a heated sheet into a bubble and it grows from 30 mm to 145 mm as pressure goes from 20 to 100 kPa, while the pole thins from 85 percent to 36. Free forming is both a production method and the best formability test there is.
Tripling the wall from 0.4 mm to 1.2 mm multiplies bending stiffness by 27, but the cracking that actually fails a corner bead falls from 22 percent to 2 percent on radius alone. Radius is the cheaper lever.
A gate narrower than about a third of the cavity depth lets the melt in as a free rope that folds on itself. Severity falls from 9 to 0 as that ratio goes from 0.15 to 0.70, and it rises again with every extra 100 mm/s of fill speed.
A calender holds thickness by the roll gap, not by a die, so a 0.2 mm silicone sheet carries an eight percent tolerance while a 2 mm sheet holds two. Cure time then falls from 60 seconds to 12 as the oven goes from 120 C to 180 C.
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