Optimal Design and Manufacture of Thin-Walled Polystyrene Structures

In this study, we investigated the implementation of an automatic procedure for optimizing thermoformed thinwalled structures. Such objects are created in great numbers, especially in the food packaging industry. The methodology for the optimal design of such structures is based on the use of a parameterized geometry model created within an interactive design environment. By varying the parameters associated with the computeraided design (CAD) model, one can create a rich variety of possible designs. One can then subject these designs to physical analysis to calculate their physical properties, and thus select an optimal design. The two distinct stages of this process—the prediction of the shape of the thermoformed structure, and the physical behavior of the structure—were validated by experiments. This article reports the experimental investigation of the deformation behavior of polystyrene, the mechanical behavior of specially prepared deformed polystyrene sheets, and the response to loading of a hemispherical structure (used in the validation). POLYM. ENG. SCI., 45: 694–703, 2005. © 2005 Society of Plastics Engineers