Frequently Asked Questions
What is thermoforming?
Thermoforming is a generic term for the process of producing plastic parts from a flat sheet of plastic under temperature and pressure. In the highest expression of the technology, thermoforming offers close tolerances, tight specifications, and sharp detail. When combined with advanced finishing techniques, high-technology thermoforming results in products comparable to those formed by injection molding. All of us are exposed to many thermoformed plastics in our daily lives. They have replaced many parts previously manufactured from wood, paper, glass, fiberglass and metal.
What are the benefits of thermoforming?
Low Pressures Required
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 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.
What kind of cosmetic features can be achieved with thermoforming?
Sharp, crisp detail with close tolerances can be achieved. Undercuts, formed-in texture, formed-in logos, formed-in hardware, and custom colors are just a few of the many features that can be accomplished with thermoforming.
What is Pressure Forming?
It is a thermoforming process similar to Vacuum Forming, with a high pressure air assist. Pressure Forming provides greater definition of part, comparable to injection molded parts with much lower tooling costs.
What size part can you make?
We specialize in single sheet, heavy gauge thermoforming. The beginning sheet size can be as large as 5’ x 8’.
What part volumes are best suited for thermoforming?
We will be most cost efficient in part runs between 1000 and 5000. We will also be more competitive in higher volumes if the part size is larger.
What materials can be thermoformed?
Parts can be produced in ABS, Polyethylene, Styrene, Acrylic, PETG, TPO, Polycarbonate, PVC and other engineered plastics. We can also thermoform Distortion printed PETG, styrene and other printable materials.
How long will my project take?
Much less time than injection molded products. Production can often start within 6 weeks after design approval.