Thermoforming Rig

Creating a tool to make windshields

Bruin Racing in university continues to expand on previous responsibilities. In freshman year, I was granted a lead position to construct a 4x4x4 ft thermoforming rig (A structure to melt plastic and shape it onto a mould using a vacuum seal). Ensuring safe handling of power tools for cutting and assembling wood and developing safety procedures for the heating elements were of utmost priority. Under this rigorous supervision, our team produced a reusable thermoforming rig over 100 times cheaper than industry standard, drawing remarks of admiration from Bruin Racing alumni. Most importantly, however, this happened with zero accidents. Having earned the additional role of a structures lead, I now also ensure the safety of all structural procedures.

Next steps

Now the requirement has changed and instead of PET-G plastic we will be using polycarbonate. While this means temperatures will have to be higher, we might still be able to use our thermoforming rig to make this happen. Hopefully, a tool that we made with the hopes of being able to use it in future years will actually be able to stand the test of time!

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