Thermoforming of plastics

Thermoforming is a catch-all term that refers to any process that uses a heated sheet of thin plastic in the development of a product or part.

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FROM: https://www.pacific-research.com/the-advantages-and-disadvantages-of-thermoforming-prl
Thermoforming is a versatile process famous in the manufacturing industry for its cost-effectiveness and relative simplicity. It’s a catch-all term that refers to any process that uses a heated sheet of thin plastic in the development of a product or part. When considering this in manufacturing, it’s smart to review the advantages and disadvantages of thermoforming to determine if it’s the best possible option for a specific product.

Thermoforming is typically part of a manufacturing strategy and not an end-to-end solution. It may create components for an overall larger piece, or act as a cover for another product. It’s a versatile process that works in just about every industry, from auto parts manufacturing to medical research. Most creators will find themselves using this process at one point or another, so understanding its strengths and weaknesses is vital.

The Different Types of Thermoforming

Thermoforming is an inclusive process, and as a result, there are hundreds of different ways companies may approach it. Some that creators should become familiar with include:

Vacuum forming: A plastic sheet in a frame is heated until it’s extremely flexible. A vacuum pulls the air out as the sheet is forced into a mold. This process is fast and cost-effective, making it ideal for high-volume work.

Pressure forming: Pressure forming follows a series of steps similar to vacuum forming, but an additional piece of tooling presses the part into place as the vacuum pulls air away. This allows for a more detailed piece with more uniform plastic thickness.

Drape forming: In this, the heated plastic sheet is draped over or pressed down onto a mandrel or form. This is a less exacting process that’s ideal when costs are a significant concern, as it’s the lowest cost when it comes to tooling or fixtures. However, what creators save in money, they also lose in terms of accuracy.

Billow forming: This process is also called “free forming” because it uses no mold. Instead, air jets blast the heated plastic into a bubble. It is used in building domes or skylights.

Matched mold forming: In this, both a male and female mold come together to force a part to take on a specific shape. This process is highly detailed, though tooling costs are much higher due to the additional pieces needed.

Twin sheet forming: Two layers are heated and formed simultaneously and then attached to create a single piece. This process works best for creating double-walled and hollow items.

Thermoforming works with both thick-gauge and thin-gauge plastic sheets, giving it a variety of uses. It’s great for things like equipment covers and housing for electronics. It’s also highly suitable in medical device creation and the development of medical models. Mostly, if the product design requires thin-walled plastic components, thermoforming could be an appropriate tool.

For long text explanations read  https://en.wikipedia.org/wiki/Thermoforming

Materials to make thermoforming molds  
~ 3D printed
~ Machine carved Aluminum
~ Machine carved wood
Learn the pros and cons of each material - https://formlabs.com/blog/thermoforming

Start testing and iterating early to avoid costly dead ends.
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That one fact should shape every question you ask before you sign anything.

FYI - Beaverton, Michigan, is known as the Plastic Thermoforming capital of the world fueled by the proximity of Dow Chemical Company of Midland, Michigan. Dow makes the dozens of specialty formulation plastic beads for making the sheet material.

Written, Compiled and Shared by:
David Bruce Savage  - Pointer Consulting

Founder and leader of the Inventor’s Education Forum in Jacksonville Florida 

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