Thermoforming is a process that embodies its namesake. Heat is used to carefully shape thermoplastic sheets. The end results are precise and replicable designs that satisfy any number of projects and plastic part needs. Though the overarching process is simple at a glance, the detail work that goes into thermoforming with Industrial Custom Products is when the impressive technology really begins to shine.
Though the overarching process is simple at a glance, the detail work that goes into thermoforming with Industrial Custom Products is when the impressive technology really begins to shine.
⇨ Read Now: Thermoforming Design Basics
How Thermoforming Works
Heat and Pressure
The thermoforming processes of Vacuum Forming and Pressure forming utilize vacuum pressure, air pressure, or some combination of both to consistently manipulate heated materials. Once shaped, parts are cooled in order to retain the shape of the design. But shape isn’t the only thing that thermoforming facilitates. During the heating process, additional features can be “baked in” to the part including applied texture, tapered edges, and undercuts that allow for stacking or detents.
Following the heating and cooling and application of these features, careful trimming and alterations are next.
There are two primary types of molds used in thermoforming – male and female.
Vacuum Forming with a Male Mold
The material is heated, stretched over a male mold, and vacuum sucks the sheet down to form into a part. With this process, the texture is already on the sheet.
Vacuum Forming with a Female Mold
The material is heated, stretched over a female mold, and vacuum sucks the sheet down to form into a part. With this process, you can get texture on the finished part two different ways:
- If the primary surface touches the mold, you can have molded textured to a wide variety of different textures.
- If the primary surface is away from the mold, then the texture will be on the sheet.
⇨ Read Now: How Thermoforming and Vacuum Forming Introduce Flexibility Into Your Production
Cooling and Finishing
After the cooling process a variety of precise alterations are made to ensure that each individual part matches exactly to the required dimensions. This may involve trimming by hand to save cost, or for many modern projects, robotically with a CNC machine. CNC machines are numerically programmed cutters that handle tolerance trimming and cutting. Though professional hand-cutting is perfect for some project needs, CNC machines come with the added benefits of extreme accuracy and precise trimming tolerances for delicate or high-yield parts.
Considerations with Thermoforming
Ultimately, thermoforming relies upon the malleability of its materials and the experts who manage the product dimensions and needs prior to forming. But, even if it’s limited to certain materials, the actual limits of thermoforming are extremely broad. Thermoplastics and the materials best suited for thermoforming are available in a wide variety of colors, textures, and thicknesses. From PE to TPO and everything in between, our thermoforming services can manage materials up to a 40” draw or .437” thick
⇨ Read Now: Troubleshooting the Thermoforming Process
Thermoforming Benefits and Applications
Thermoforming holds many advantages over other processes including injection molding. Some of these advantages include:
- MUCH lower tooling costs
- Shorter tooling lead times
- Faster product development (rapid prototypes)
- Cost-effective production of large parts
Thermoforming can be used for many applications. It can be used for both incredibly small plastic parts as well as large plastic parts. Some industries that use thermoforming applications include:
- Recreation
- Medical
- Fitness
- Lawn & Garden
- Agriculture
- Heavy Truck
- Electronics
- Retail Merchandising
- Consumer Products
- Commercial Equipment
- Filtration
- Energy
- Automotive
- Telecommunications
⇨ See What Thermoforming Can Do
Contact Thermoforming Experts
Industrial Custom Products offers a variety of tools and methods for producing the parts that you envision for the projects that you care about. Contact us and speak with an engineer about your project at (612) 781-2255, or request a quote online. You will receive a prompt response.
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.
