Formech Technical Newsletter - Plug Assist: usage, types, & tips

Depending on your application, the use of a plug assist can be beneficial. What is it used for? Which Formech machines have a Plug Assist? What types of Plug Assist does Formech offer? Follow the guide to get all the answers to your questions.

What is a Plug Assist useful for?

• Reduces the thinning of material on deep draw or multiple cavities formings
• Avoids the distortion of the formed part during the release process
• Helps prevent some materials (such as Acrylic (PMMA)) from cracking during the release process
• Stops webbing when tall or closely spaced tools are being formed (see picture below)

Which Formech machines have a Plug Assist?

• HD Range (as optional)
• TF Range (as standard)
  

What types of Plug Assist does Formech offer?

• Pneumatic Plug Assist – this type is controlled by a pneumatic cylinder and has only one speed in each direction (up and down).
• Servo Plug Assist – this type can be programmed to have multiple staged descent and ascent at different speeds. It provides much more control when compared to pneumatic-powered ones.

Can I use a plug with other Formech machines?

• You can create your own manually operated plug but this comes with its own challenges. Watch the video below for more information:

Useful tips when designing and mounting a plug:

• The shape of the plug will vary depending on where you want the material to be the thickest.
• As a rough guideline, a plug will be in the region of 80% the size of the cavity and should descend 70 – 75% of the depth of the cavity
• The plug can be made from wood, resin, solid felt, metal covered with suede or leather, model board or tooling board, syntactic foams (composite materials - Hytac).
• Pack the plug with spacers so that it is in the centre of the cavity. Apply foam tape to the top of the plug and bring down the pneumatic or servo plug. Once you are happy with its positioning, secure it with screws or bolts.
  
  
  

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