Exploring the Wide Application Range of Thermoforming in Various Industries

1. Strong Adaptability

Thermoforming is a highly adaptable process capable of producing a wide variety of parts, ranging from extremely large to very small, thick to thin. The thickness of the raw material sheets (or films) can be as thin as 1-2mm, or even thinner. The surface area of thermoformed products can reach up to 10 m², typically in the form of semi-shell structures, with sizes as small as a few square millimeters. Wall thicknesses can range from 0.1mm to 20mm. For instance, a thermoformed tablet packaging can have a wall thickness as thin as 0.05mm. The majority of thermoformed products have a concave or convex semi-shell shape, and the depth has some limitations.

2. Wide Application Range

Due to the strong adaptability of thermoformed parts, they have a broad application range. Thermoforming is used to produce items from pill packaging to refrigerator liners and even aircraft cabin covers. Common products include cups, plates, household items, medical devices, electronic equipment components, radio and television casings, billboards, bathtubs, toys, helmets, and packaging materials. Thermoforming is also used for automotive components, building elements, chemical equipment, radar domes, and aircraft cabin covers.

3. Low Equipment Investment

Thermoforming equipment is simple, requiring minimal investment. Since the process does not demand high pressures, the equipment does not require complex or expensive machinery, making it a cost-effective manufacturing solution.

4. Simple Mold Manufacturing

The molds used in thermoforming are relatively simple in structure, made from low-cost materials, and easy to fabricate and modify. Materials such as steel, aluminum, plastic, rubber, and even stone can be used to create molds. The cost of thermoforming molds is approximately one-tenth that of injection molds, and product designs can be quickly altered, making this process suitable for small batch production.

5. High Production Efficiency

When using multi-cavity molds, thermoforming can achieve high production rates, with output reaching up to several hundred pieces per minute.

6. High Waste Utilization

Most thermoforming processes generate scrap material, especially when using sheet or film to produce circular parts, which can result in up to 50% or more scrap. For rectangular products, the scrap rate may be around 25%. To minimize waste, these scrap materials can be mixed with new materials for reuse in subsequent production runs.