Thermoforming Uncovered: Heavy Gauge Techniques and the Rise of Plastic Solutions

This article is about thermoforming, which is a very versatile process used to create plastic components, and the article will touch on its durability, design flexibility, and cost-effectiveness. It will discuss some unique capabilities of thermoforming, the different plastics that can be used with thermoforming, and how thermoforming is targeted in relation to other processes like injection molding. Understanding these features allows designers and manufacturers to make better decisions about their products.

What Is Thermoforming?

Thermoforming refers to a method in which an actual plastic sheet is heated and shaped using vacuum, pressure or twin-sheet methods. Partnering with a reliable thermoforming company ensures precision, consistency, and efficiency throughout the process. Thermoforming is a relatively low-cost and rapid method of processing plastic, and can be done to many different types of materials (e.g. styrene, ABS, polycarbonates, etc.). Vacuum forming only exerts a firm grasp of the heated plastic, while pressure forming utilizes additional force to achieve sharper / cleaner detail and texture features. Twin-sheet forming utilizes two sheets that are fused together, producing strong and very lightweight hollow parts. Thermoforming can be used for a variety of products from very simple trays, to multi-piece, complex enclosure products.

Heavy Gauge Thermoforming: When Thickness Matters

Heavy-gauge thermoforming is a process that uses heavier sheets, typically thicker than 3 millimeters (inches), to form rigid components. Unlike methods used by injection molding companies, this approach relies on thicker materials that require more robust tooling and longer heating and cooling cycles. However, the increased performance and durability of the parts, along with precision characteristics and suitability for demanding industries, make it a great fit for their needs. Heavy-gauge thermoforming is often used for automotive interior features, as well as protective equipment housings for various industries, and various industrial enclosures. Because of the materials being thicker for heavy-gauge thermoforming, the upfront tooling costs tend to be lower, as well as are quicker to produce than the multi-step methods, especially for medium-volume production runs.

Thermoforming Plastics: Material Options and Properties

Thermoforming involves the use of different types of plastic material each of which was introduced into the environment with different properties. The material can be ABS, which has toughness and impact resistance properties, polycarbonate, which has strength and optical clarity considerations, PVC, which also has chemical resistance considerations, and polypropylene, which is very lightweight and has durability properties as well. HDPE offers both chemical and wear resistance features. In the end, engineers need to characterize the mechanical properties, thermal properties, chemical resistance properties, UV exposure properties and the texture of the material to make sure the final product performs well in its environment.

Thermoforming vs. Injection Molding

Although thermoforming and injection molding are similar, they are also different in many ways. In general, thermoforming needs lower tooling costs and lead times; it is ideally suited for low to medium volumes. Injection molding requires a larger upfront investment but is efficient when manufacturing high-volume runs. However, thermoforming works best with the manufacture of larger parts, faster development cycles, and lower costs.

Conclusion

Thermoforming is a cost-effective and efficient production method, especially for heavy gauge applications. Thermoforming allows for the production of quality, durable parts without the costs incurred with injection molding as long as the right plastic is chosen to suit fabrication guidelines.