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The Problem
A university research project required two bespoke baffle tubes manufactured from ultra-thin 50-micron FEP sheet. The finished component needed a precise series of grooves around the circumference while maintaining a smooth, consistent profile throughout the tube.
Due to the thinness of the material, conventional fabrication methods risked introducing distortion that would affect both the appearance and dimensional accuracy of the finished part.
The Solution
Adtech produced a seamless FEP tube by welding 50-micron FEP sheet using a butt welding process. The tube was then formed into the required baffle profile using a vacuum forming technique developed to create the customer’s specified groove pattern around the circumference.
This approach allowed the finished component to achieve the required geometry while retaining the properties of the FEP material.
The Challenges
Working with 50-micron FEP presented several manufacturing challenges. At this thickness, the material is highly flexible and susceptible to creasing, which could have affected the final appearance and consistency of the component.
A smooth weld area was also essential. Any ridge or irregularity along the weld line would transfer into the formed profile and become visible on the finished baffle tube.
To overcome this, Adtech designed and manufactured bespoke welding equipment specifically for the small tube diameter. This enabled the production of a flat, seamless weld and provided a stable starting point for the subsequent vacuum forming process.
The Result
The project was successfully completed with two bespoke FEP baffle tubes manufactured to the required profile. The combination of precision butt welding and vacuum forming produced a smooth, consistent component with the specified circumferential grooves, demonstrating Adtech’s ability to fabricate complex parts from extremely thin fluoropolymer materials.
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