Thermoformed Parts – Ideal for Vehicle Construction

Thermoformed plastic parts are increasingly playing a significant role in vehicle manufacturing due to their cost-efficiency and flexibility in design. The advantages include:

• Low Tool Costs: Thermoforming offers lower costs compared to many other processes.
• Fast Development and Manufacturing: The tools can be quickly developed and modified.
• Short Reaction Times: Design changes and model cycles can be handled swiftly.
• Cost-Effective for Small Batches: Even small quantities can be economically produced with prototype tools.
• Durability in Series Production: Mould tools are long-lasting, capable of producing up to 100,000 parts.
• Large Moulds at Lower Costs: Even large mould sizes are affordable in thermoforming.

Thermoforming also offers a variety of material options, including:

• Through-Coloured Plastics: Available in a wide range of colors, including metallic options.
• UV Stabilized Plastics: Resistant to UV damage.
• Surface Variety: Matte, high-gloss, and metallic finishes are possible.
• Design Precision: Sharp corners, edges, and two-sided designs can be achieved.
• Lightweight: The final product is lightweight, contributing to overall vehicle efficiency.
• Recyclable: 100% recyclable materials are used.

The Advantages of Thermoforming for Vehicle Parts

Moulded thermoformed parts offer high flexibility in design and production. Key advantages include:

• Lightweight: Thermoformed parts are light yet strong, ideal for vehicle applications.
• Color and Surface Customization: Thermoformed parts can be produced in various colors, including metallic finishes, without the need for additional painting.
• Surface Quality: Thermoformed parts can feature high-quality design surfaces, whether matte, high-gloss, or soft-touch.
• Cost-Effective for Small Batches: Thermoforming is particularly advantageous for producing small series economically.
• Competitive Production Quantities: Topthermoforming technology supports competitive production up to 100,000 parts per year.

Thermoforming Processes: Positive vs. Negative Forming

Depending on the desired outcome for shape and surface quality, thermoformed parts can be produced using either positive or negative forming.

Positive Forming

In this process, the tool is placed at the bottom of the plastic sheet, and the sheet is pulled over the tool. The visible side remains uncontacted, resulting in high-gloss or metallic finishes. Benefits include:

• High Surface Quality: Glossy and metallic surfaces are easily achievable.
• Variety of Grooves: The ability to produce complex groove patterns.
• Shaped Radii: Wall thicknesses are primarily defined by the sheet’s thickness but can still be shaped effectively.

Negative Forming

Here, the plastic sheet is pulled into the mould, with the visible side of the sheet contacting the tool. This method offers:

• Fine Edges and Detail: The tool can have intricate radii and edge curves, with strong undercuts.
• Injection-Moulded Look: Surfaces can be etched for perfect injection-moulded finishes.
• Flexible Surface Definition: Surface textures can be precisely defined and tailored.

Positively Formed Body Parts – High Gloss and Shaped

Positively formed vacuum-moulded parts, such as fenders, engine hoods, and front grills, offer:

• Through-Coloured Plastics: No need for painting, as the parts are made from through-coloured plastics with high-gloss surfaces.
• Shaped Radii: The parts can include carefully designed radii for a functional yet aesthetic body design.
• Pre-Assembled Parts: Attachments can be pre-integrated during production for easy assembly on vehicles.

Example parts produced by TopThermoforming include:

• Left and right fenders
• Engine hood
• Mirror triangle
• Front grill
• Door panels (front and rear)

Positively Formed Interior Parts – Functional and Elegant

The thermoforming process is ideal for producing high-quality interior parts. For electric vehicles, the benefits of thermoforming are clear:

• Quick Development Times: The process allows for rapid prototyping and production adjustments during development.
• Aesthetic Surface Finishes: The surface structure of the plastic sheet directly defines the design, ensuring both functionality and beauty.
• Perfect Integration: Interior parts such as door panels, center consoles, and dashboards are seamlessly integrated into the vehicle design.

Key parts include:

• Door panels
• Centre consoles
• Boot linings
• Dashboard covers

The Topthermoforming Group – Expertise in Thermoforming

Founded in 2005, TopThermoforming is a leader in the development and production of high-quality vacuum-moulded parts. With decades of expertise, the company has become one of the most important thermoforming firms in Europe, offering:

• State-of-the-Art Machinery: Equipped to produce parts for a wide range of industries.
• Commitment to Quality: All processes are ISO-certified, ensuring the highest standards of quality.
• Sustainability: TopThermoforming is certified under EMAS, emphasizing its commitment to environmental responsibility.

Full Range of Services

Topthermoforming offers a comprehensive range of services to ensure every project is a success:

Expert Advice and Planning

• Customized Consultation: TopThermoforming’s project-specific planning groups ensure that customer needs are met from the outset.

High-Tech CAD Design

• Collaborative Development: In close partnership with clients, TopThermoforming engineers handle everything from initial sketches to complex CAD models.

Fast and Flexible Prototyping

• Quick Turnaround: Prototypes are quickly produced using high-quality tools, allowing for swift modifications based on customer feedback.

Series Production with Consistent Quality

• High-Volume Capability: State-of-the-art machinery and 3-shift production enable high-volume production while maintaining excellent quality.

Sophisticated Logistics

Optimized Delivery: topthermoforming logistics ensure timely delivery and easy

Your Powerful Partner for Thermoformed Parts

With over 19 years of expertise, topthermoforming remains committed to customer satisfaction through:

• Flexibility: Providing solutions that meet diverse needs with flexibility and reliability.
• High-Quality Standards: Focused on maintaining the highest levels of quality and customer satisfaction in every aspect of the production process.

As a trusted partner for thermoformed parts, Topthermoforming is equipped to meet both current and future demands in the vehicle construction industry.