A Guide to Thermoforming Tooling Types
When looking at a completed plastic part, it can be hard to see all of the decisions that led to this final form. From design to material selection to the actual manufacturing process - dozens of decisions at each stage culminate in a superior completed project.
One of these vital decisions in the manufacturing process is the type of tooling to use. For thermoformed parts, tooling can literally make or break a part. In this guide, we’ll cover the most common types of thermoforming tooling types and their ideal applications.
What is Thermoforming?
As a refresher, thermoforming is the process of heating sheets of thermoplastic until they’re pliable, and then molding them to a tooling shape using suction from a vacuum. From there, pieces are trimmed either by hand or with a CNC machine.
The advantage of thermoforming over other plastic fabrication processes is that it has lower tooling costs and shorter lead times. This makes it a great choice for lower-volume parts, particularly parts that are large (such as hoods, shields, panels, etc.).
Related Content: Thermoforming Design Basics
Thermoforming Tooling and Mold Types
There are a few different types of tooling that can be used with the thermoforming process. Core in the thermoforming tooling process are the molds used during production. Each offers different advantages for different applications. To find the best fit for your part, contact a thermoforming design expert.
Water Cooled Cast Aluminum Tooling
In this method, a mold made out of aluminum is used. The mold is created by the process of casting - where liquid-hot aluminum is poured into a mold and then cooled. The advantage here is that the surface can be extremely detailed. This can be used to create molds out of aluminum that will then be used in thermoforming processes. Alongside the aluminum mold, water is used to rapidly cool the plastic. This process is useful for parts at production levels due to longevity of the tooling and faster cycle times.
Billet Aluminum Tooling
A billet aluminum tool is likewise made out of aluminum, but following a different process than casting. For this type of mold, it’s created out of a solid cross-section of aluminum (called a billet) which is then cut into to create the mold. This option creates a mold that is much stronger than a cast mold. In order to cool the part more quickly, a chill plate is located underneath the mold. It’s also a slightly lower cost typically than a cast aluminum mold. This tooling type is beneficial for production quantities with parts that have a shallow depth of draw.
3D-Printed Tooling
As you might guess from the name, a 3D-printed tooling process involves a mold created by 3D-printing. We partner with Catalysis to source our 3D-printed molds. Unlike metal molds, 3D-printed molds are porous and non-conductive. These types of molds are ideal for parts where timelines are tight and budgets are important. They can be used for lower-volume production or as a good option for prototyping as well.
Thermoforming Prototype Tooling Types
Before a part is put into production, prototyping tooling may be needed. There are two popular choices for thermoforming tooling prototypes.
Polyurethane Board Tooling
We can create prototypes using machine polyurethane board tools. The advantage of this material for creating prototype tooling is that these can be manufactured in a shorter time period at a lower cost than production tooling. They’re also available in several densities, so you can mock up a prototype for a future metal tool using a dense and rigid polyurethane board.These tools are not water cooled, so they are only used for prototypes and very low volume runs.
Wood Prototype Tooling
We create prototype tooling using wood, which can include molds, fixtures and patterns. Creating prototypes before executing the real thing can help improve the manufacturability of the completed part. Wood can be a good choice for prototyping, as it’s significantly lower-cost compared to aluminum tooling. The drawback is that there are limitations on design and materials we recommend using as it is more prone to expansion and delamination.
Selecting the right tooling for your application is a vital part of the production process. For guidance on your project, choose ICP’s product development services. We work seamlessly alongside your teams to ensure optimal performance and a superior end product.
Industrial Custom Products is a one-stop-shop for custom manufacturing and plastic fabrication, including: prototyping and product development, die cutting and dieless knife cutting, thermoforming and vacuum forming, large part thermoforming, CNC plastic routing, fabrication and assembly and drape forming.