Towards simulation-based optimization of the thermoforming process of lightweight acrylic bathtubs

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Hytec, a division of Kohler Canada, produces gelcoat and acrylic baths, showers, modular bathing systems and shower bases with diverse designs and structures . Thermoforming, a well-known cost-effective yet complex process in the industry sector, has been used at Kohler as the primary approach to manufacturing bathtubs and shower bases. However, the occasional occurrence of defects, such as cracks, webbings, and plastic sheet tearing, requires costly repairs or sometimes even reject parts that significantly impact the final cost of parts.The absence of robust data collection infrastructure for monitoring the process, as well as the complexity and uncertainty in the thermal and mechanical aspects of the thermoforming process turns investigating the process characteristics and detecting the sources of the failures into a laborious and challenging task for Kohler's engineers.The goal of the proposed ENGAGE project is to help Hytec to start developing advanced numerical models that can predict the quality of thermoforming parts, and hence to mitigate potential defects ahead of actual manufacturing trials. Such models are deemed particularly useful for cases where the manufacturer would like to e.g. produce bathtub parts with new shapes.