Thermoforming is a process where plastic sheets are heated to a specific temperature and molded into the desired shape using molds. It is widely used for manufacturing custom plastic parts, especially in the production of plastic shells, containers, and other complex shapes. Compared to other plastic forming processes, thermoforming offers significant advantages, providing efficient, cost-effective, and flexible production solutions.

Why Consider Using the Thermoforming Process?

The main advantages of thermoforming are its shorter production cycle, lower costs, and precise control over part shape and dimensions. Compared to injection molding or die-casting processes, thermoforming has lower mold costs, making it ideal for small-batch production. This process is especially suitable for custom and flexible designs.

Comparison of Thermoforming and Other Plastic Forming Processes

The following table summarizes the advantages and disadvantages of thermoforming in comparison to other common plastic forming processes:

Industries That Benefit from Custom Thermoformed Plastics

Custom thermoformed plastics, with their flexible process, are widely used across many industries. Here are some key sectors that benefit from this technology:

• Automotive Industry: Used for interior and exterior parts, dashboard components, trim, and window frames.
• Home Appliances: Used for TV covers, refrigerator shells, washing machine panels, etc.
• Electronics: Used for electronic product housings, display stands, control panels, and more.
• Packaging: Includes food packaging, medical packaging, display packaging, etc.
• Medical Industry: Includes housings for medical devices and portable equipment.

Maximum Size and Thickness Range

Custom thermoformed plastics can be produced in a wide range of sizes and thicknesses. The typical ranges are as follows:

• Maximum Size: The maximum thermoforming size can reach 3000mm × 1500mm, depending on the thermoforming machine and mold used.
• Maximum Thickness: Plastic sheets typically range from 0.5mm to 8mm in thickness, although some high-performance materials can be thermoformed up to 10mm or more.

Common Thermoforming Materials

Thermoforming can be used with a variety of plastic materials. The choice of material depends on the product’s functional requirements, operating environment, and cost considerations. Common materials include:

1. ABS: Commonly used for appliance housings, automotive parts, and luggage. It has excellent impact resistance and weatherability but poor solvent resistance. Variants like ABS+UV, ABS+Food Grade, ABS+Cold Resistant, and ABS+Fire Resistant are also available.

2. HIPS (High Impact Polystyrene): More economical than ABS, commonly used for display products and packaging. It has lower strength but still offers decent impact resistance.

3. PMMA (Acrylic): High strength but brittle, suitable for applications requiring good transparency, such as bathtubs, skylights, and signage.

4. PC (Polycarbonate): Offers excellent impact resistance, suitable for applications requiring high strength such as aircraft decor, light diffusers, and security shields. PC also provides good transparency and is widely used in protective applications.

5. PETG: Known for its high impact resistance, suitability for food contact, and scratch resistance. Commonly used in food packaging and display applications.

6. HDPE (High-Density Polyethylene): Flexible, high-impact strength, and cost-effective, commonly used for vehicle parts, custom plastic enclosures, and other similar applications.

Main steps of custom thermoforming

1. Providing 3D Drawings or Product Samples
   The customer must first provide detailed product designs, such as 3D drawings or actual samples. This information will serve as the foundation for subsequent production.
2. Consultation and Quotation
   Based on the customer’s requirements, a professional team will provide technical advice and offer a quotation based on factors such as design complexity and quantity, ensuring the customer understands production costs and timelines.
3. Mold Creation
   After finalizing the design, technicians will create high-precision molds according to the customer’s specifications. The quality of the mold directly affects the accuracy and appearance of the final product, making this step crucial.
4. Vacuum Forming Production
   The plastic sheet is heated to a specific temperature and then placed over the mold to form the initial shape. This phase ensures the material evenly conforms to the mold, creating the preliminary shape.
5. CNC Processing
   After vacuum forming, CNC machining is used to refine the product, ensuring precise dimensions and a smooth surface for the final product.
6. Polishing and Deburring
   The finished product undergoes surface polishing to remove any burrs and improve its appearance and feel, ensuring it meets customer expectations.
7. Additional Treatments
   Depending on the customer’s specific needs, post-processing treatments such as bonding, painting, and silk-screen printing are applied to meet various functional and aesthetic requirements.
8. Quality Testing
   After completing all processes, the product undergoes comprehensive functional and quality testing to ensure it meets the defined standards and customer expectations.
9. Packaging and Shipping
   Once all steps are completed, the product is carefully packaged to prevent damage during transport, and timely shipping is arranged to ensure the customer receives it without delay.

With our extensive capabilities, we can produce a diverse range of customized plastic parts and components to cater to your specific needs. Whether you require packaging trays, display items, automotive components, or medical device housings, we have the knowledge and expertise to bring your ideas to life.