Abstract
Moulding is a method of inducing a permanent three-dimensional shape in ther moplastic materials by heat setting. Using polyurethane foam moulding for brassiere pads as an example, the most essential problem is to predict the optimum conditions that result in the best cup shape conformity with the most efficient use of heat energy. To study the best moulding quality, a response surface method is used to examine the relationship between a measured response (shape conformity) and a number of input variables (moulding temperature and time). The optimum moulding conditions for individual foam types can be found by examining the contour plots of response sur faces. A relationship between the moulding temperature and time is then derived. The heat energy required for optimum moulding can be expressed in terms of these two moulding variables and three other foam attributes ( mass, specific heat, and thermal conductivity).
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