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Line speed rises from 8 to 30 m/min as the cure tunnel goes from 140 to 200 C, and compression set falls from 28 to 9 percent over the same range. The faster line is also the better seal, which is not the trade most people expect.
A 0.5 mm hole takes 3.5 seconds to pull full vacuum and leaves a visible mark on no parts. A 3 mm hole takes 0.5 seconds and marks 95 percent of them. The whole design problem is that the two curves run in opposite directions.
Cross-direction thickness spread falls from 0.12 mm to 0.02 mm as die adjuster spacing goes from 100 mm to 25 mm. Output rises from 320 to 700 kg/h as the sheet widens from 1,000 to 2,500 mm. Width buys output; adjusters buy tolerance, and they are not the same purchase.
Shot weight variation bottoms out at 0.30 percent with a 6 mm cushion and climbs to 0.90 percent at 12 mm, because a large cushion means a long residence time. Decompression past 2 mm produces drool on 7 shots in a hundred.
Calendered silicone sheet holds plus or minus 0.05 mm on thickness, moulded sheet holds 0.15 and extruded sheet 0.25. The same material, the same hardness, three processes and a five-fold difference in what the sheet can be specified to.
A wood pattern gives a first-off part 1.2 mm off drawing against 0.1 mm for aluminium, but it costs a tenth as much and arrives in days. It accumulates 40 hours of repair over 5,000 parts, where an aluminium tool needs four. The question is which of those two numbers your program can afford.
Gloss falls from 88 to 38 units as the chill roll goes from 10 C to 50 C, and forming shrinkage rises from 1.2 to 3.6 percent over the same range. You cannot have a glossy sheet and a predictable one from the same setting.
Shot weight variation falls from 0.90 percent to 0.30 as back pressure goes from zero to 10 bar, and then barely moves. The melt temperature rises 26 degrees over the same range, and the last 20 bar buys 0.06 percent of consistency for 19 degrees of heat.
Burst pressure peaks at 22 bar when the braid crosses the hose axis at 54.7 degrees, and falls to 11 bar at 80. It is not a manufacturing preference, it is the angle at which the fibres carry pressure in tension instead of trying to straighten.
An epoxy tool is ready in five working days against forty for steel, and it grows 0.15 mm in the cavity at 80 C against a part tolerance of 0.10. The limit is not wear, it is thermal expansion, and it arrives long before the tool is worn out.
Yellowness index runs 1.2 at 280 C and 14 at 360 C, so twenty degrees roughly doubles it. Drying takes eight hours at 100 C and two at 130 C, and the same moisture that hydrolyses the chain also leaves the sheet hazy.
Cooling time runs 4 seconds at a 1 mm wall and 36 at 3 mm, because it follows the square of thickness. A mould 20 degrees colder saves eight seconds a cycle and buys distortion, which is the trade nobody puts on the cycle sheet.
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