Thermoforming Process Critical to Success of Project
Choosing the right thermoforming process for your project can be challenging, as there are many factors to consider. In this blog, we will compare and contrast three common thermoforming methods: vacuum forming, pressure forming, and twin sheet thermoforming. We will also provide some guidelines on how to select the best option for your specific needs and goals.
Common Thermoforming Processes
VACUUM FORMING is a thermoforming process that uses a vacuum to draw the heated plastic sheet into a mold. This creates a smooth and uniform surface on the part, as well as a consistent wall thickness. Vacuum forming is ideal for applications that requiring lower tooling costs, or fast production cycles. Some examples of vacuum formed products are trays, containers, and signs.
PRESSURE FORMING is a thermoforming process that enhances the vacuum with additional pressures, to force the heated plastic sheet against a mold. This creates a high level of detail and texture on the surface of the part, as well as sharp edges and corners. Pressure forming is ideal for applications that require complex shapes, high aesthetics, or tight tolerances. Some examples of pressure formed products are medical device enclosures, automotive dashboards, and electronic housings.
TWIN SHEET THERMOFORMING is a thermoforming process that uses two heated plastic sheets that are fuse together in a mold. This creates a hollow part with two walls, and an internal cavity. Twin sheet thermoforming is ideal for applications that require structural strength, rigidity, or insulation. Some examples of twin sheet thermoformed products are pallets, tanks, and ducts.
Factors Used in Determining Best Thermoforming Process
To determine which thermoforming process is the best choice for your plastic thermoformed project, you need to consider several factors, such as:
- The size and shape of the part
- The level of detail and texture required on the surface
- The wall thickness and strength of the part
- The tooling and material costs
- The production volume and speed
By weighing these factors against the advantages and disadvantages of each thermoforming method, you can select the most suitable option for your project. ATI’s expertise in the thermoforming industry makes us the go to resource for help with all your design and thermoform production needs. Contact us today to get started with your custom thermoforming project!
