Computer simulation of thermoforming in complex shapes

Abstract A finite element analysis of thermoforming based on the thin membrane approximation is presented. Triangular elements with adaptive mesh refinement are used to describe deformed shapes in complex geometries. Viscoelastic effects are assumed to be negligible, and Ogden's model is used to express the material response. The results are in good agreement with previous simulations and some experimental data available in the literature. The combination of adaptive mesh refinement near corners and edges, inclusion of slip or no‐slip conditions as required on mold walls, and an efficient equation solver allow simulation of thermoforming in complex geometrical shapes at reasonable computer times on a personal computer.