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Frequently Asked Questions About Thermoforming and Plastic Component Production

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As thermoformer specializing production of plastic components, we work with you to bring your vision to life. Our team has the expertise to aid in designing a functional part and selecting the best material for your application. Use these FAQs to learn more about the thermoforming process.

Q.

What is thermoforming?

A. Thermoforming is the process of molding plastic sheets over or into a mold using heat and vacuum. To achieve the final product, thermoforming may utilize several different types of molds and processes.

Q.

How does thermoforming work?

A. To thermoform a plastic product:

  1. A sheet of plastic material is clamped into a thermoformer and sent into an oven for heating.

  2. Once the plastic reaches the right temperature for processing, it’s transferred to a mold, where vacuum assists in forming the part.

  3. The formed part is then cooled, removed from the mold and sent to the next station for trimming.

Q.

Now that I know the basics of thermoforming, how is it different from injection molding?

A. Although the quality and detail of parts manufactured from both processes are similar, there are a few differences. The tooling for thermoformed parts is much less expensive. This is because injection molding tools require a cavity and a core, while the tooling used in the thermoforming process is one-sided. Because of this, parts get to production quicker. Another difference is that the tooling used in thermoforming can be easily and affordably modified in the event of a product design change.

Q.

There are so many material choices – how do I know which one is best?

A. When selecting a material for your project, you should consider the end use of the part and how you expect the part to perform.. Factors such as UV exposure, flame resistance and durability may all affect which material is best suited for your application. There is a wide range of thermoforming materials that provide just the right properties for your plastic formed product. Learn about six of the more common thermoforming materials. Still undecided? We can help you determine the right material for your project.

Q.

Can thermoforming be used to make something other than packaging?

A. Although thin-gauge packaging is common, there are many other thermoformed parts you probably don’t realize you see every day. You can find these parts in cars and trucks, on medical devices and even on farm equipment! Thermoforming can produce parts made from very thin material (.005”) or thick, sturdy material up to .500”, although most parts are made from sheet between .062” to .375” thick.