Thermoforming is the process of forming a thermoplastic sheet into a 3-dimensional shape by clamping the sheet in a frame, heating it to render it soft, then applying differential pressure to make the sheet conform to the shape of a mold or die positioned below the frame.

What are the Benefits of Thermoforming?

• Relatively Low Tooling Costs
  Thermoforming compares favorably with other methods such as injection molding because of the low pressures required. Prototypes and short runs can use tooling of wood, plaster, epoxy, aluminum or similar materials. Machined or cast aluminum is used in production.
• Better Physical Properties In Finished Part
  In thermoforming, the heated sheet is virtually stress free compared to other polymer manufacturing methods.  When properly formed, the sheet is almost completely stretched at the forming temperature before it is cooled against the mold. This, of course, sets up a very minimum of internal stress in the finished part.
• Ability To Take Advantage Of Multiple Layer Sheet Material
  Up to nine separate layers of various materials have been extruded so far, as well as the use of press laminated sheet and extrusion laminated sheet. Thermoforming technology makes full use of multiple layer sheet material.
• Pressure Forming Detail: This method offers detail on the mold side comparable to injection molding with 1/10th the tooling cost and much faster initial delivery.
  
• Ability to Produce Parts With Very High Strength Reinforcement Composites
  Sheet materials containing graphite, boron or fiberglass can be successfully produced.
• Ability To Form Very Large Parts
  Relative to other processing methods, part sizes up to 5 ft. x 8 ft. [1.524 x 2.44 m] can be thermoformed easily and economically.

Thermoforming Foam Sheet

Foam sheet, from thin to heavy gauge, is readily thermoformed. Products such as egg cartons, automotive interior side and dash panels, seat cushions, athletic pads, shoe sections and industrial packaging are all in production.  Polyester and Polyethylene foam sheets can also be thermoformed.

Pre-Decoration of Sheet

Sheet material can be economically extruded/laminated and thermoformed with many finishes such as:

• Textures
• Printed patterns (e.g., wood grains)
• Acrylic caps for high gloss, high detailed finish
• Distorted graphic or normal printing