When it comes to cultivating mushrooms, having the right environment is crucial. At Terrashroom, we’ve engineered our polycarbonate dome to not only protect your mushrooms but also to provide the optimal conditions for growth. But have you ever wondered how these durable, transparent domes are made? Let’s take a behind-the-scenes look at the process that turns high-quality polycarbonate sheets into the essential structure that houses your mushrooms.
Step 1: Material Selection
The journey of a Terrashroom TS-01 polycarbonate dome begins with the careful selection of materials. Polycarbonate is chosen for its exceptional durability, impact resistance, and clarity. This material ensures that the dome can withstand various environmental conditions while still allowing light to penetrate—an important factor in mushroom cultivation. The selected polycarbonate sheets must meet strict criteria for thickness and transparency, ensuring they are up to the task.
Step 2: Cutting and Shaping
Once the right polycarbonate sheets are selected, they are cut to the required size and shape. This step is vital, especially if the dome has a specific curvature or design. Precision cutting ensures that the material will fit perfectly over or into the mold during the forming process. At this stage, the sheets are ready to be transformed into the recognizable dome shape.
Step 3: Thermoforming or Molding
The heart of the dome-making process is thermoforming or molding. Here, the cut polycarbonate sheet is heated to a precise temperature where it becomes pliable and moldable. Once the sheet reaches the ideal state, it is carefully placed over or into a custom mold shaped like the dome. Using pressure or vacuum, the sheet is then forced to conform to the mold’s contours, ensuring a perfect fit and uniform thickness throughout the structure. This step is crucial for creating a strong, resilient dome that can stand the test of time.
Step 4: Cooling and Setting
After the polycarbonate has been molded into the dome shape, it’s time to let it cool and set. Cooling allows the material to harden and retain its new shape. This process must be done gradually to prevent any warping or internal stress that could compromise the dome’s integrity. Once cooled, the dome is solid, clear, and ready for the next steps.
Step 5: Trimming and Finishing
With the dome now fully formed, the next step involves trimming away any excess material and smoothing the edges. This is also the stage where any necessary openings, such as for ventilation or wiring, are carefully drilled or cut. The goal is to ensure that the dome is not only functional but also aesthetically pleasing, with clean, smooth lines and edges.
Step 6: Assembly
If the Terrashroom TS-01 dome is made up of multiple parts, this is where they are brought together. Using high-strength adhesives, mechanical fasteners, or even ultrasonic welding, the various components are assembled into a single, cohesive structure. This assembly process is done with precision to ensure the dome remains strong and secure once fully constructed.
Step 7: Quality Control
Quality control is a crucial part of the process. Each dome undergoes a thorough inspection to ensure there are no defects such as bubbles, cracks, or distortions in the polycarbonate. The domes are also tested for durability and transparency, ensuring they meet the high standards required for Terrashroom products. Only after passing these stringent checks is a dome considered ready for use.
Step 8: Packaging and Shipping
The final step in the journey is packaging. Once the dome passes all quality checks, it is carefully cleaned, securely packaged, and prepared for shipping. Whether it’s going to a hobbyist or a commercial grower, each dome is handled with care to ensure it arrives in perfect condition, ready to create the ideal environment for mushroom cultivation.
