Thermoforming is a plastic forming process that has transformed the way we create custom plastic parts. With its versatility and efficiency, it plays a crucial role in various industries, from packaging to prototyping.

Thermoformed plastic products are used in a wide range of applications including food packaging, pharmaceuticals and electronics. Food trays, yoghurt tubs, sandwich packs and blister packs are all thermoformed products, and we all use them every day.

Imagine being able to shape thermoplastic materials into intricate designs with just heat and pressure—that’s the magic of thermoforming! No matter which industry you are from, understanding this process can open up new possibilities for innovation. Dive in as we share what thermoforming is all about and how it can elevate your projects to the next level!

What is Thermoforming?

Thermoforming is a manufacturing process that shapes thermoplastic materials into desired forms. It involves heating plastic sheets until they become pliable and then molding them using various techniques. At its core, this method harnesses heat to make the material flexible enough for shaping. Once heated, the softened plastic can be draped over or pressed into molds to create parts with intricate details.

This technique is widely appreciated for its efficiency and cost-effectiveness. Companies favor thermoforming because it allows for quick production runs while minimizing waste of raw materials. Common applications range from packaging solutions to components used in electric vehicles and drones. Its adaptability makes thermoforming an attractive choice in many industries looking to innovate and enhance their product offerings.

How does thermoforming work?

Thermoforming is a plastic forming process that begins with heating thermoplastic sheets. These sheets are warmed to their pliable state, making them easy to mold. Once softened, the heated sheet is placed over a mold. This can be done using either vacuum or pressure forming methods. Vacuum forming uses suction to draw the material tightly against the mold surface, while pressure forming involves pushing air onto the sheet for more defined shapes. As the plastic cools and solidifies, it takes on its new form. The result is a durable component tailored for specific applications.

The speed of this process allows manufacturers to create prototypes quickly or produce custom plastic parts efficiently. From packaging solutions in various industries to components for electric vehicles and drones, thermoforming holds significant value across sectors. Each step ensures precision and flexibility in design.

Thermoforming Materials

Thermoforming materials are the backbone of this versatile plastic forming process. Commonly used thermoplastic materials include ABS, PETG, PVC, and polystyrene. Each material offers unique properties that cater to different applications.

• Acrylonitrile-Butadiene-Styrene (ABS): The characteristics of ABS include rigidity, resistance to abrasion, and resistance to low temperatures. Manufacturers can leverage thermoforming and ABS to produce electronic packaging, food containers, and domestic appliances.

• Polyethylene Terephthalate (PET): PET provides very good alcohol and essential oil barrier properties, good chemical resistance, and a high degree of impact resistance and tensile strength. It is commonly used for carbonated beverages, water bottles, and many food products

• Polyvinyl Chloride (PVC): PVC is another popular plastic used in manufacturing pipes, window frames, automotive interiors, domestic items, packages, and footwear. PVC can be developed to be either rigid or flexible depending on the manufacturer’s requirements. This thermoplastic is also dense, durable, and resistant to water. It is important to note that PVC isn’t completely chemical resistant and may react to chlorine.

• Polystyrene (PS): This aromatic hydrocarbon polymer provides manufacturers with a clear, hard, and brittle plastic to work with. Polystyrene is widely used as a thermoforming packing material as it offers qualities such as resistance to water and air. Manufacturers use polystyrene to manufacture food packaging, jewel cases, CD cases, and domestic items.

• Polypropylene (PP): PP is the most popular plastic material for thermoforming in terms of value and volume. It is commonly used in manufacturing packages, ventilators, toys, and other plastic items. Polypropylene is used because of its innate properties such as excellent resistance to chemicals, fatigue, and heat. Polypropylene is also an affordable material and can be used with the diverse thermoforming processes highlighted here.

• Low-Density Polyethylene (LDPE): LDPE is a thermoplastic that is resistant to chemicals and UV rays. This plastic is also flexible and has high tensile strength. Manufacturers can utilize LDPE to manufacture packaging films, DVDs, cable insulation, containers, and chemical-resistant items.

• High-Density Polyethylene (HDPE): HDPE is similar to LDPE in terms of its base characteristics and is noted as being resistant to chemicals, UV rays, and water. It is a durable thermoplastic that may be used to manufacture packaging film, blown bottles, containers, pipes, and plastic bags

• Polycarbonate (PC): Polycarbonates are strong, tough materials that can undergo ​​large plastic deformations without cracking or breaking. They’re heat-resistant, flame-retardant, and have good electrical insulator properties. Some grades of PC are also optically transparent and highly transparent to visible light. PCs are used for plastic lenses in eyewear, in medical devices, automotive components, protective gear (lenses, safety helmets), bullet-proof glass, car headlamps, and construction.

• Polymethyl methacrylate (PMMA): The properties of PMMA include high strength, resistance to weather elements, durability, and transparency. Manufacturers take advantage of PMMA to produce lenses, headlamps for vehicles, and transparent packaging. The durability of PMMA ensures that end-use parts serve their purpose for the long term.

Choosing the right thermoforming material greatly influences product performance and functionality within diverse applications across many sectors.

Applications for Thermoforming

There are many different products/processes which make use of thermoforming such as:-

• Open type plastic panels and containers

• Food containers and packaging

• Refrigerator internal door

• Plastic sign boards and signs

• Home appliances like sink unit, bath tubs and shower panels

• Parts of automotive – specially interior (video below)

• Dinghy hulls

• Contoured skylights

• Electrical enclosures

• Braille text pages

• Electrical cabinet

Type of Thermoforming Processes

Thermoforming processes can be categorized primarily into two types: vacuum forming and pressure forming.

Vacuum forming is the most common method. It uses heat to soften thermoplastic sheets, which are then draped over a mold. A vacuum pulls the sheet tightly against the mold’s surface, creating various shapes. This technique is ideal for simple designs and for larger parts and production runs of less than or up to 10,000 units.

On the other hand, pressure forming enhances detail and precision. After heating, air pressure pushes the plastic onto the mold's contours more forcefully than in vacuum forming. This results in sharper details and improved finishes—perfect for complex applications.

Benefits & Limitations

Thermoforming offers several advantages that make it a popular choice in the manufacturing sector. One significant benefit is its cost-effectiveness for low to medium production runs. The initial mold design can be less expensive than injection molding, allowing businesses to save on upfront costs.

Additionally, the process allows for rapid prototyping. Designers can quickly create custom plastic parts and test designs without lengthy lead times.

However, there are limitations as well. Thermoformed parts typically have lower strength compared to those made by injection molding. This might not suit applications requiring high durability or complex geometries.

Moreover, material selection can be restrictive in some cases since only thermoplastic materials work with this process. Understanding these strengths and weaknesses helps manufacturers choose the right method for their projects effectively.

Applications of Thermorming

Thermoforming is a versatile technique used across various industries.

In packaging industry, it allows for the creation of custom trays and clam-shells that offer excellent protection for products. This method enhances shelf appeal while ensuring durability.

In the automotive sector, thermoformed parts contribute significantly to lightweight designs, improving fuel efficiency in electric vehicles. Thermoplastics can be molded into complex shapes that fit modern aesthetics and functional requirements.

The medical industry also benefits from this process by producing sterile packaging and components tailored to specific needs. Custom plastic parts facilitate better usability in healthcare applications. It provides an economical and attractive solution to manufacturing quality, large and aesthetically pleasing enclosures, panels, trays, covers and sidewalls. Thermoformed medical devices offers lower cost tooling for large part production and much quicker lead times to market which is often important in the medical device field.

Aerospace industry also utilizes thermoforming, with streamlined body components designed for agility and performance. The aerospace industry is increasingly, recognizing their value in reducing weight without sacrificing structural integrity.

From prototyping new concepts to mass production runs, thermoforming finds its place everywhere innovation thrives.

Thermoforming vs. Injection Moulding

When comparing thermoforming and injection moulding, it's essential to understand the unique advantages each process offers. Thermoforming is often favored for its simplicity and cost-effectiveness, particularly in low to medium production runs. It allows for rapid prototyping and quick adjustments in mold design, making it an excellent choice for custom plastic parts.

On the other hand, injection moulding excels in high-volume production where precision is critical. This method can create intricate designs with tight tolerances that are hard to achieve through thermoforming. However, the initial investment for injection moulding equipment is significantly higher than that of thermoforming setups.

Thermoforming processes like vacuum forming or pressure forming shine when working with thermoplastic materials such as ABS or polypropylene. These techniques enable manufacturers to produce large sheets into complex shapes efficiently while keeping costs manageable.

Both methods play vital roles across various industries including packaging, automotive components (like those used in electric vehicles), and even drone technology. Choosing between them ultimately depends on your specific project needs—be it scalability, complexity of design or budget constraints.

Each plastic forming process has its merits; understanding these will help you make informed decisions tailored to your application requirements.

You don’t need to be an expert, we are. 

Make Production Orders with Thermoforming at Procurabl

The thermoforming process stands as a pivotal method in the realm of manufacturing, offering versatile solutions for shaping various materials. Its adaptability across industries, including automotive, medical, and packaging, underscores its practicality.

For businesses seeking reliable solutions for low and mid-volume production, Procurabl offers top-notch thermoforming services.

Procurabl specializes in sourcing solutions for the manufacturing company's direct material categories. Our platform enhances supplier discovery and sourcing, offering intuitive tools for quick insights and identifying cost-saving opportunities.

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Reach out to us! We're eager to help procurement professionals leverage e-sourcing tools to transform their daily workflows and achieve exceptional results.