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This Headboard is used on a bariatric bed system. It's function, in addition to being a headboard, is to provide a handle to move the bed. What is unique about the part is that it is twin-sheet molded with an aluminum weldment for structure "insert-molded" into the part during the molding process (part of the weldment is shown extending from the part in view 2). The challenge the "insert-molding" creates in the twin-sheet process is the delay between the sheets leaving the oven and forming to the mold, and the time it takes to load the inserts, all the while the sheet is losing heat and jeopardizing the integrity of the weld. Exacerbating this challenge is the fact that we trim the weld "flush", as shown in view 1, removing some surface area necessary for a strong weld. Various process controls and molding techniques allow us to overcome these challenges. The mold has an articulating feature (core-pull) that positions the weldment correctly during the process, and then retracts to allow de-molding. View 3 is a label recess molded using the pressure-form technique. The recess had tight radii defining it and making for a pleasing cosmetic pocket for the label. Once the part is trimmed, it is then foam-filled for additional structure and stiffness. Then a colored polycarbonate overlay is attached in another pressure-formed recess. |
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